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Table of Contents

   Summary of Contents for Kawasaki Z750

  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Sep. 16, 2003 (M)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

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

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

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

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

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

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

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

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

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

    1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ...
  • Page 25: Periodic Maintenance

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

    FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 82: Dfi Servicing Precautions

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

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

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

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

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

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

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

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 101 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis...
  • Page 102: Main Throttle Sensor (service Code 11)

    3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 103: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor (gray) [A] and con- nect the harness adapter [B] between these connectors.
  • Page 104: Resistance Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 105: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank (see Fuel System chapter) Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B] •...
  • Page 106: Output Voltage Inspection

    3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 107 FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then Pv = 70 –...
  • Page 108 3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Volt- ID: Idling age (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) TO: Throttle Full Open Ps: Standard Atmospheric Pressure (abso- ST: Standard of Sensor Output Voltage (v) lute)
  • Page 109: Inlet Air Temperature Sensor (service Code 13)

    (see ECU section in this chapter). If the wiring is good, check the sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of ECU Connectors...
  • Page 110: Sensor Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. •...
  • Page 111: Water Temperature Sensor (service Code 14)

    4.8 V, the ECU is normal. If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of ECU Connectors...
  • Page 112: Sensor Resistance Inspection

    3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to the Electrical System chapter for water temper- ature sensor inspection.
  • Page 113: Atmospheric Pressure Sensor (service Code 15)

    FUEL SYSTEM (DFI) 3-51 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○ The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring.
  • Page 114: Output Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 115 FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output ST: Standard of Sensor Output Voltage (v) Voltage (v) H: Altitude (m or feet) UR: Usable Range of Sensor Output Voltage (v) A. ECU E. Atmospheric Pressure Sensor...
  • Page 116: Crankshaft Sensor (service Code 21)

    3-54 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 117: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-55 Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the camshaft position sensor.
  • Page 118: Speed Sensor (service Code 24, 25)

    3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Speed Sensor Inspection • See the Switches and Sensors section in the Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 119 FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001–1400 •...
  • Page 120: Vehicle-down Sensor (service Code 31)

    3-58 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Connection and Vehicle-down Sensor [A] Bolts [B] Installation • The UP mark [A] of the sensor should face upward.
  • Page 121 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.
  • Page 122 3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) A. ECU a. ECU Fuse 15 A f. Sealed Battery S. ECU Main Relay b. Vehicle-down Sensor j. Joint Connector B T. Ignition Switch d. Starter Relay k. Main Fuse 30 A...
  • Page 123: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 124: Output Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing.
  • Page 125: Resistance Inspection

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 126: Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

    3-64 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 127 FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) A. ECU X. Ignition Fuse 10 A f. Sealed Battery M. Stick Coils Y. Junction Box k. Main Fuse 30 A N. Engine Stop Switch d.
  • Page 128: Subthrottle Valve Actuator (service Code 62)

    3-66 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.
  • Page 129: Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-67 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the throttle body assy (see Throttle Body Assy Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 130: Fi Indicator Led Light

    3-68 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 131: Led Light Inspection

    FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) BR/W Lead Terminal [1] of the Meter →...
  • Page 132: Ecu

    3-70 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame chapter) Junction Box [A] • Take the ECU [A] out along with the harness. •...
  • Page 133 FUEL SYSTEM (DFI) 3-71 • With the ECU connectors [A] connected, check the fol- lowing ground lead for continuity with the ignition switch OFF, using a tester and needle adapter set. ECU Grounding Inspection 26, 50, or 51 (BK/Y) ←→ Battery (–) Terminal: 0 Ω Terminal Engine Ground ←→...
  • Page 134 3-72 FUEL SYSTEM (DFI) ECU Power Source Circuit A. ECU a. ECU Fuse 15 A f. Sealed Battery S. ECU Main Relay d. Starter Relay j. Joint Connector B T. Ignition Switch e. Joint Connector C k. Main Fuse 30 A...
  • Page 135: Dfi Power Source

    FUEL SYSTEM (DFI) 3-73 DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 136: Fuel Line

    3-74 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well.
  • Page 137: Fuel Pump Removal

    FUEL SYSTEM (DFI) 3-79 Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set. Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○ Measure the operating voltage with the engine stopped, and with the connector joined.
  • Page 138: Fuel Pump Relay Removal

    3-80 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the storage compartment.
  • Page 139: Fuel Injectors

    FUEL SYSTEM (DFI) 3-81 Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 140: Output Voltage Inspection

    3-82 FUEL SYSTEM (DFI) Fuel Injectors Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU section). • Connect a digital voltmeter [A] to the ECU connector [B] with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage Connections to Injector #1 Meter (+) →...
  • Page 141: Injector Signal Test

    FUEL SYSTEM (DFI) 3-83 Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.071 in.) Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above.
  • Page 142: Injector Resistance Inspection

    3-84 FUEL SYSTEM (DFI) Fuel Injectors Injector Resistance Inspection • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector from the injector [A] (see Throt- tle Body Assy Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Special Tool - Hand Tester: 57001–1394 Injector Resistance Connections to Injector...
  • Page 143 FUEL SYSTEM (DFI) 3-85 Fuel Injectors • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with the clamps [D]) as shown.
  • Page 144 3-86 FUEL SYSTEM (DFI) Fuel Injectors A. ECU Y. Junction Box f. Sealed Battery K. Fuel Injectors Z. Fuel Pump Relay (for fuel j. Joint Connector B N. Engine Stop Switch pump an injectors) k. Main Fuse 30 A T. Ignition Switch d.
  • Page 145: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-87 Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Choke Lever Operation ○ Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10°C, 50°F or below) or at high altitude.
  • Page 146: Throttle Body Assy

    3-88 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Engine Vacuum Synchronization Inspection/ Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. High Altitude Performance Adjustment •...
  • Page 147 FUEL SYSTEM (DFI) 3-89 Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cleaner Duct Clamp Bolts [B] • Remove: Right and Left Side Covers (see Frame chapter) Coolant Reserve Tank (see Cooling System in the Peri- odic Maintenance chapter) Crankcase Breather Hose Right and Left Air Cleaner Housing Mounting Bolts [A]...
  • Page 148: Throttle Body Assy Installation

    3-90 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the bolt [A] and the throttle cable plate [B] from the throttle body front side. • Remove the throttle cable lower ends from the throttle pulley. • Remove: Choke Cable Upper End (From choke lever) Choke Cable Lower End [A] •...
  • Page 149: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-91 Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar.
  • Page 150: Throttle Body Assy Assembly

    3-92 FUEL SYSTEM (DFI) Throttle Body Assy CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. • Pull out the injectors along with the delivery pipe [A]. If necessary, remove the injectors from the delivery pipe. Replace the O-rigs of the indicators.
  • Page 151: Air Cleaner

    FUEL SYSTEM (DFI) 3-93 Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. •...
  • Page 152: Fuel Tank

    3-94 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 153: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-95 Fuel Tank • Be sure to place a piece of cloth [A] around the fuel hose pump outlet joint [B]. • While pinching the hose joint locks [C] with fingers, pull the joint out along the delivery pipe. WARNING Be prepared for fuel spillage;...
  • Page 154: Fuel Tank And Cap Inspection

    3-96 FUEL SYSTEM (DFI) Fuel Tank • Insert the pump outlet hose joint [A] straight onto the de- livery pipe [B] until the hose joint clicks [C]. Front [D] • Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 155 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools and Sealant ...................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............
  • Page 156: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 157 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator hose clamp screws 0.20 17 in·lb Radiator fan bolts 0.85 74 in·lb Water pump impeller bolt 87 in·lb Water pump cover bolts 95 in·lb Water pump drain bolt 95 in·lb Water pipe bolts 95 in·lb...
  • Page 158: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 159 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 10. Reserve Tank Hose 2. Water Pump 11. Reserve Tank Overflow Hose 3. Cylinder Jacket 12. Radiator Fan 4. Cylinder Head Jacket 13. Water Temperature Sensor 5. Thermostat Housing 14. Radiator Fan Switch 6.
  • Page 160: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping: Permanent type of antifreeze (soft water and ethylene glycol Type (recommended) plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point –35°C (–31°F) Total amount...
  • Page 161: Special Tools And Sealant

    COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver: Kawasaki Bond (Silicone Sealant): 57001–382 56019–120 Bearing Driver Set: 57001–1129...
  • Page 162: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 163: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
  • Page 164: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Inspection •...
  • Page 165: Cylinder Head

    5-20 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 166 ENGINE TOP END 5-21 Valves Valve Clearance Inspection • Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 167 5-22 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 168 ENGINE TOP END 5-23 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 169 5-24 ENGINE TOP END Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 170 ENGINE TOP END 5-25 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 171 5-26 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 172 ENGINE TOP END 5-27 Valves...
  • Page 173 5-28 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Water Hose [A] • Remove the cylinder [B]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the dowel pins [A] and new cylinder gasket [B]. •...
  • Page 174 ENGINE TOP END 5-29 Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 175 5-30 ENGINE TOP END Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its marking hollow facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.
  • Page 176 ENGINE TOP END 5-31 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 177 5-32 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 178: Throttle Body Holder

    ENGINE TOP END 5-33 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that its hole fit on the projection [C] of the holder. • Tighten: Torque - Throttle Body Holder Bolts [D]: 13 N·m (1.3 kgf·m, 113 in·lb)
  • Page 179: Radiator

    5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolt [A] Muffler Body Mounting Bolt [B] •...
  • Page 180 ENGINE TOP END 5-35 Muffler ○ Install the muffler body clamp bolt as shown. Upper Side [H] Outside [I] • Thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts.
  • Page 182 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 183: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 184 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch lever clamp bolts 0.80 69 in·lb Clutch cover mounting bolts 95 in·lb Oil filler plug 0.15 13 in·lb Clutch spring bolts 0.90 78 in·lb Clutch hub nut CL: Apply cable lubricant. EO: Apply engine oil.
  • Page 185: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch: 37.7 ∼ 38.3 mm (1.48 ∼ 1.51 in.) Clutch plate assembly – – – 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction plate thickness 2.4 mm (0.094 in.) Friction and steel plate warp...
  • Page 186: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001–1243 56019–120...
  • Page 187: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch in the Periodic Maintenance chapter. Cable Removal • Slide the dust cover [A] at the clutch cable lower end out of place.
  • Page 188: Clutch Lever Adjustment

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 189: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Replace the clutch cover gasket with a new one. •...
  • Page 190: Clutch Cover Disassembly

    CLUTCH 6-9 Clutch Cover • Fit the spring [A] as shown. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Circlip [A] Oil Level Gauge [B] Clutch Cover Assembly •...
  • Page 191: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C], spring and washer) •...
  • Page 192 CLUTCH 6-11 Clutch ○ Install the spacer [A] so that the tapered side [B] faces inward. ○ Install the washer [A] so that the OUTSIDE mark faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001–1243 Torque - Clutch Hub Nut: 135 N·m (14 kgf·m, 100 ft·lb) •...
  • Page 193: Clutch Plate Assembly Inspection

    6-12 CLUTCH Clutch • Apply molybdenum disulfide grease to the pusher ends [A] and install the bearing [B], pusher [C], spring [D] and washer [E] in the clutch spring plate [F]. ○ Apply engine oil to the needle bearing. • Install the clutch spring plate, springs and spring holders, and tighten the clutch spring bolts.
  • Page 194: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-13 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 196 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 197: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 198 L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019–120). W: Apply water.
  • Page 199 7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 200: Engine Oil Flow Chart

    ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Passage Hole in Alternator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Filter 7. Oil Pressure Switch 8.
  • Page 201: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 202: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001–164 57001–1249 Oil Pressure Gauge Adapter, PT3/8: Kawasaki Bond (Silicone Sealant): 57001–1233 56019–120...
  • Page 203: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 204: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Exhaust Pipe Assy and Muffler Body (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] Oil Pan Installation •...
  • Page 205: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 206: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: Coolant (see Cooling System in the Periodic Mainte- nance chapter) Engine Oil (see Engine Lubrication System in the Peri- odic Maintenance chapter) • Remove: Water Pipe Bolts [A] Water Pipes [B] •...
  • Page 207: Oil Pump Drive Gear Removal

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Pins [A] Water Pump Body [B] • Install: Impeller [A], Washer and Bolt [B] • Tighten: Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Pins [C] Water Pump Cover and Bolts Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
  • Page 208: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Measurement Oil Pressure Measurement • 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, PT 3/8: 57001–1233 •...
  • Page 209: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead direction upward.
  • Page 210 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 211: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 212 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting collar locknut Upper engine mounting bolts Rear engine bracket bolts Front engine bracket bolts Middle engine mounting nut Lower engine mounting nut Engine ground cable terminal bolt 87 in·lb 8.
  • Page 213: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001–1450...
  • Page 214: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 215 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Camshaft Position Sensor Connector [A] Injector Harness Connector [B] • Remove the vacuum switch valve hose from the air cleaner housing. • Remove: Breather Hose End [A] Engine Ground Cable Terminal Bolt [B] •...
  • Page 216: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the middle and lower engine mounting nuts [A] and bolts. • Remove: Rear Engine Bracket Bolts [B] Rear Engine Bracket [C] • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001–1450 •...
  • Page 217 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...
  • Page 218 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation ○ Tenth, temporarily install: Front Engine Bracket [C] Right Upper Engine Mounting Bolt [A] Front Engine Bracket Bolts [B] ○ Eleventh, tighten the right upper engine mounting bolt. ○ Lastly, tighten the front engine bracket bolts. Torque - Right Upper Engine Mounting Bolt : 44 N·m (4.5 kgf·m, 33 ft·lb) Front Engine Bracket Bolts: 44 N·m (4.5 kgf·m, 33...
  • Page 220 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Inspection ... 9-22 Specifications ........Starter Motor Clutch Disassembly 9-22 Special Tools and Sealant ....Starter Motor Clutch Assembly ..9-22 Crankcase Splitting......9-10 Transmission ........9-23 Crankcase Splitting ...... 9-10 Shift Pedal Removal ....
  • Page 221: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 222 EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104–1066). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Tightening the fasteners following the specified sequence.
  • Page 223 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 224 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift pedal mounting bolt Gear positioning lever bolt 104 in·lb Shift shaft return spring pin Shift drum cam holder bolt 104 in·lb Footpeg bracket bolts Shift lever bolt 0.70 61 in·lb Tie-rod locknuts 0.70 61 in·lb...
  • Page 225: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting rod twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting rod big end side clearance 0.58 mm (0.0051 ∼...
  • Page 226 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 0.05 ∼ 0.20 mm Crankshaft side clearance 0.40 mm (0.0020 ∼ 0.0079 in.) (0.0157 in.) TIR 0.05 mm Crankshaft runout TIR 0.02 mm (0.0008 in.) or less (0.0020 in.) Crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm 0.07 mm (0.0008 ∼...
  • Page 227 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 6.9 ∼ 7.0 mm Shift fork guide pin diameter 6.8 mm (0.272 ∼ 0.276 in.) (0.268 in.) 7.05 ∼ 7.20 mm Shift drum groove width 7.3 mm (0.278 ∼ 0.283 in.) (0.287 in.)
  • Page 228: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Bearing Puller: Kawasaki Bond (Silicone Sealant): 57001–135 56019–120 Bearing Puller Adapter: Kawasaki Bond (Silicone Sealant): 57001–317 92104–1066...
  • Page 229: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Clutch (see Clutch chapter) External Shift Mechanism (see External Shift Mecha- nism Removal)
  • Page 230 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply liquid gasket to the breather plate mating surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - Three Bond: 1207B • Apply a non-permanent locking agent to the threads and tighten the bolts [A].
  • Page 231 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Silicone Sealant): 92104–1066 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. •...
  • Page 232: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 233 9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide grease [A] to the outer sur- face of the upper insert and the inner surface of the con- necting rod big end. • Apply molybdenum disulfide oil [B] to the inner surfaces of upper and lower bearing inserts.
  • Page 234 CRANKSHAFT/TRANSMISSION 9-15 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 235: Crankshaft/connecting Rod Cleaning

    9-16 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 and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution.
  • Page 236: Connecting Rod Bend

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 237: Connecting Rod Big End Bearing Insert/crankpin Wear

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance with plastigage [A]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○ Do not move the connecting rod and crankshaft during clearance measurement.
  • Page 238: Crankshaft Side Clearance

    CRANKSHAFT/TRANSMISSION 9-19 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 239: Crankshaft Runout

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear •...
  • Page 240 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase Main Bearing Inside Diameter Marks : " " or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 241: Starter Motor Clutch

    9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Electrical System chapter) Starter Idle Gear • Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
  • Page 242: Transmission

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Footpeg Bracket Bolts [A] Footpeg Bracket [B]...
  • Page 243: External Shift Mechanism Removal

    9-24 CRANKSHAFT/TRANSMISSION Transmission • Install the footpeg bracket [A]. • Tighten: Torque - Footpeg Bracket Bolts [B]: 34 N·m (3.5 kgf·m, 25 ft·lb) • Install the shift lever [A], aligning the mark (previously marked). • Tighten: Torque - Shift Lever Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 244: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-25 Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Collar and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 245: Transmission Shaft Removal

    9-26 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.
  • Page 246: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-27 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shafts. •...
  • Page 247 9-28 CRANKSHAFT/TRANSMISSION Transmission NOTE ○ When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○ When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28] (see Page 9–29).
  • Page 248 CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. 1st Gear 18. Bushing 2. 2nd Gear 19. Bushing 3. 3rd Gear 20. Circlip 4. 4th Gear 21. Ball Bearing 5. 5th Gear 22. Collar 6. 6th (Top) Gear 23. Washer 7. Toothed Washer, 31 mm (1.22 in.) 24.
  • Page 249: Shift Drum And Fork Removal

    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts External Shift Mechanism (see External Shift Mecha- nism Removal) Bolt [A] and Screw [B] Shift Drum Bearing Holder [C] • Pull out the shift rods [D], and take off the shift forks. •...
  • Page 250: Shift Fork Bending

    CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear •...
  • Page 252 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 ......................10-9 Axle Inspection........................
  • Page 253: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 254 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front axle clamp bolt Front axle Rear axle nut G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 255: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial – – – TIR 0.5 mm (0.020 in.) Radial – – – TIR 0.8 mm (0.031 in.) Axle runout/ TIR 0.05 mm (0.0020 in.) or less TIR 0.2 mm 100 mm (3.94 in.) (0.008 in.) Wheel balance...
  • Page 256: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001–1129 57001–1293 Jack: Bearing Remover Shaft, 13: 57001–1238 57001–1377...
  • Page 257: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] • Loosen the front axle clamp bolt [A]. • Remove the front axle [B]. • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 •...
  • Page 258: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the front axle. Torque - Front Axle: 108 N·m (11 kgf·m, 80 ft·lb) • Before tightening the clamp bolt on the right front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle.
  • Page 259: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Caliper Mounting Bolts [A] Caliper [B] • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove the wheel from the rear caliper. • Remove the rear wheel.
  • Page 260: Wheel Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • Adjust the drive chain slack after installation (see Final Drive chapter).
  • Page 261: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Remove the front and rear axles. • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
  • Page 262: 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 263: Tires

    10-12 WHEELS/TIRES Tires Air Pressure Inspection • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Tire Wear Inspection in the Periodic Mainte- nance chapter. Tire Removal • Remove: Wheel (see Front Wheel Removal, Rear Wheel Re- moval) Disc(s) Valve Core (let out the air)
  • Page 264 WHEELS/TIRES 10-13 Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal with a soap and water solution or rubber lubricant, and pull [B] the valve stem [A] through the rim from the inside out until it snaps into place.
  • Page 265: 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 266: Hub Bearing

    WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals Circlip • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 268 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 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication..................... 11-6 Drive Chain Removal ......................
  • Page 269: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 270 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine sprocket cover bolts 87 in·lb Engine sprocket nut Rear sprocket nuts Speed sensor cover bolts 0.70 61 in·lb Speed sensor bolt 0.70 61 in·lb Rear axle nut G: Apply grease. HO: Apply heavy oil.
  • Page 271: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain: 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Chain slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 20-link length 323 mm (12.7 in.) Standard chain Make ENUMA –...
  • Page 272: Special Tools

    FINAL DRIVE 11-5 Special Tools Bearing Driver Set: Jack: 57001–1129 57001–1238...
  • Page 273: 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. Drive Chain Wear Inspection •...
  • Page 274: Drive Chain Replacement

    FINAL DRIVE 11-7 Drive Chain Drive Chain Replacement • Remove: Chain Cover (see Drive Chain Removal) Engine Sprocket Cover (see Engine Sprocket Removal) EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting & Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H]...
  • Page 275 11-8 FINAL DRIVE Drive Chain • Replace the link pin, link plate and grease seals. • Apply grease to the link pins [A] and grease seals [B] [C]. • Engage the drive chain on the engine and rear sprockets. • Insert the link pins in the drive chain ends.
  • Page 276 FINAL DRIVE 11-9 Drive Chain • Turn pin holder until riveting pin touches link pin. • Turn wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Some work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 277: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Connector [A] Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 278: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 279: Coupling Installation

    11-12 FINAL DRIVE Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001–1129 Coupling Installation •...
  • Page 280: Sprocket Wear Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection).
  • Page 282 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Brake Pad Wear Inspection ..12-14 Specifications ........12-6 Master Cylinder ......... 12-15 Special Tool ........12-7 Front Master Cylinder Removal ... 12-15 Brake Lever, Brake Pedal....12-8 Front Master Cylinder Installation 12-15 Brake Lever Position Adjustment.
  • Page 283: Exploded View

    12-2 BRAKES Exploded View...
  • Page 284 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front caliper mounting bolts Brake hose banjo bolts Bleed valve 0.80 69 in·lb Brake lever pivot bolt 0.10 9 in·lb Brake lever pivot bolt locknut 0.60 52 in·lb Front brake disc mounting bolts Front brake light switch screws 0.10 9 in·lb...
  • Page 285 12-4 BRAKES Exploded View...
  • Page 286 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear master cylinder push rod locknut Rear caliper mounting bolts Brake hose banjo bolts Bleed valve 0.80 69 in·lb Rear master cylinder mounting bolts Rear brake disc mounting bolts B: Apply brake fluid. G: Apply grease.
  • Page 287: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position 5-way adjustable (to suit rider) – – – Brake lever free play Non-adjustable – – – Pedal free play Non-adjustable – – – Pedal position About 47 mm (1.85 in.) below footpeg top –...
  • Page 288: Special Tool

    BRAKES 12-7 Special Tool Jack: 57001–1238...
  • Page 289: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 290: Calipers

    BRAKES 12-9 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).
  • Page 291: Front Caliper Disassembly

    12-10 BRAKES Calipers Front Caliper Disassembly • Remove: Front Caliper (see Caliper Removal) Brake Pads and Springs (see Brake Pad Removal) • Using compressed air, remove the pistons. ○ Cover the piston area with a clean, thick cloth [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to remove the piston.
  • Page 292: Rear Caliper Disassembly

    BRAKES 12-11 Calipers • Replace the fluid seals [A] with new ones. ○ Apply brake fluid 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 293: Rear Caliper Assembly

    12-12 BRAKES Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 294: Caliper Piston And Cylinder Damage

    BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visually inspect the piston [E] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Fluid Seal [A] Dust Seal [B] Rubber Boot [C] Front Caliper [J] Rear Caliper [K] Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder...
  • Page 295: Brake Pads

    12-14 BRAKES Brake Pads Front Brake Pad Removal • Remove the caliper from the disc. • Draw out the holder shaft pin [A], and take off the holder shaft [B]. • Remove the pad [C] on the piston side. • Push the holder [D] towards the piston, and remove the pad of the other side [E] from the holder shaft [F].
  • Page 296: Master Cylinder

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder [C] (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [A], and take off the master cylin- der as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 297: Rear Master Cylinder Removal

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation). • Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. •...
  • Page 298: Rear Master Cylinder Disassembly

    BRAKES 12-17 Master Cylinder Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal). •...
  • Page 299: Brake Disc

    12-18 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 300: Brake Fluid

    BRAKES 12-19 Brake Fluid Brake Fluid Level Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brakes in the Periodic Maintenance chapter. Brake Line Bleeding • Refer to the Brakes in the Periodic Maintenance chapter.
  • Page 301: Brake Hose

    12-20 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 302 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal ......................13-8 Front Fork Installation ....................... 13-8 Front Fork Oil Change ...................... 13-8 Front Fork Disassembly ....................13-9 Front Fork Assembly......................
  • Page 303: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 304 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 Front fork bottom Allen bolts Front axle clamp bolt 6. Right fork leg 7. Left fork leg AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 305 13-4 SUSPENSION Exploded View...
  • Page 306 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear shock absorber nuts (upper and lower) Swingarm pivot shaft nut Swingarm pivot shaft locknut Rocker arm nut Tie-rod bolts...
  • Page 307: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube outside diameter 41 mm (1.61 in.) Air Pressure Atmospheric pressure (Non-adjustable) Fork spring setting Non-adjustable Damper setting Non-adjustable Fork oil viscosity KAYABA KHL34-G10 Fork oil capacity 452 ±4 mL (15.28 ±0.135 US oz.) (completely dry) approx.
  • Page 308: Special Tools

    SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: Fork Oil Seal Driver: 57001–183 57001–1288 Fork Cylinder Holder Adapter: Fork Oil Level Gauge: 57001–1057 57001–1290 Oil Seal & Bearing Remover: Hook Wrench: 57001–1058 57001–1539 Bearing Driver Set: Swingarm pivot Nut Wrench: 57001–1129 57001–1541 Jack:...
  • Page 309: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal • Remove: Front Wheel (see Tires/Wheels chapter) Front Fender (see Frame chapter) Fairing (see Frame chapter) Loosen the handlebar bolt, upper fork clamp bolt and fork top plug before-hand if the fork leg is to be disassembled. NOTE ○...
  • Page 310: Front Fork Disassembly

    SUSPENSION 13-9 Front Fork • Hold the outer tube vertically in a vise and compress the fork completely. • Wait until the oil level stabilizes. • Use the fork oil level gauge [A] to measure the distance between the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001–1290 ○...
  • Page 311 13-10 SUSPENSION Front Fork • Remove the cylinder unit [A], washer, and the spring [B] from the inner tube. • Remove the following from the top of the outer tube: Dust Seal [A] Retaining Ring [B] • Separate the inner tube [A] from the outer tube [B]. NOTE ○...
  • Page 312: Front Fork Assembly

    SUSPENSION 13-11 Front Fork Front Fork Assembly • Check the top plug O-ring and replace it with a new one. • Replace the following parts with new ones: Retaining Ring [A] Dust Seal [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Fork Bottom Allen Bolt Gasket [F] •...
  • Page 313: Inner Tube/outer Tube Inspection

    13-12 SUSPENSION Front Fork Inner Tube/Outer Tube Inspection • Visually inspect the inner tube [A] and repair any nicks or rust by using an oil stone. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal slip, replace the oil seal whenever the inner tube is repaired or replaced.
  • Page 314: Rear Shock Absorber

    SUSPENSION 13-13 Rear Shock Absorber Rebound Damping Force Adjustment • Turn the damper adjuster [A] to adjust the rebound damp- ing. ○ Align the numbered mark [B] of the adjuster. ○ The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is position "2".
  • Page 315: Rear Shock Absorber Installation

    13-14 SUSPENSION Rear Shock Absorber • Remove: Lower Shock Absorber Nut [A] Lower Shock Absorber Bolt [B] • Remove: Upper Shock Absorber Nut [A] Upper Shock Absorber Bolt [B] • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation •...
  • Page 316: Swingarm

    SUSPENSION 13-15 Swingarm Swingarm Removal • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: Chain Cover (see Final Drive chapter) Mud Guard (see Frame chapter) Brake Hose Clamp [A] Rear Wheel (see Wheels/Tires chapter) Lower Shock Absorber Nut and Bolt [A] Upper Tie-rod Nut and Bolt [B] •...
  • Page 317: Swingarm Installation

    13-16 SUSPENSION Swingarm Swingarm Installation ○ Place the collar [A] on the stopper [B] inside the frame [C]. • Insert the pivot shaft into the frame from the right side. • Tighten the pivot shaft so that the clearance [D] between the collar and the frame come to zero mm.
  • Page 318: Swingarm Bearing Installation

    SUSPENSION 13-17 Swingarm Swingarm Bearing Installation • Install the needle bearings so that the manufacturer’s marks face in. • Install the ball bearing so that the manufacturer’s marks faces out. Special Tool - Bearing Driver Set: 57001–1129 [A] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection.
  • Page 319: Tie-rod, Rocker Arm

    13-18 SUSPENSION Tie-rod, Rocker Arm Tie-rod Removal • Remove the side stand (see Frame chapter). • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 320: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-19 Tie-rod, Rocker Arm Rocker Arm/Tie-rod Bearing, Sleeve Inspection • Visually inspect the rocker arm/tie-rod sleeves and needle bearings. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.
  • Page 322 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 Stem Bearing Lubrication....................14-8 Steering Stem Warp......................
  • Page 323: Exploded View

    14-2 STEERING Exploded View...
  • Page 324 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering stem nut Steering stem head bolt Front fork clamp bolts (Upper) Front fork clamp bolts (Lower) Handlebar clamp bolts Handlebar lower clamp nuts Switch housing screws 0.36 31 in·lb 8.
  • Page 325: Special Tools

    14-4 STEERING Special Tools Steering Stem Nut Wrench: Steering Stem Bearing Driver: 57001–1100 57001–1344 Bearing Driver Set: Steering Stem Bearing Driver Adapter: 57001–1129 57001–1345 Jack: 57001–1238...
  • Page 326: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering in the Periodic Maintenance chapter. Steering Adjustment • Refer to the Steering in the Periodic Maintenance chapter.
  • Page 327: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Inner Cover (see Frame chapter) Fairing and Bracket (see Frame chapter) Front Wheel (see Wheels/Tires chapter) Handlebar (see Handlebar Removal) Steering Stem Head Bolt Plug Steering Stem Head Bolt [A] and Washer Front Fork Clamp Bolts (Lower) (Loosen) Steering Stem Head •...
  • Page 328: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. • Apply grease to the outer races, and drive them into the head pipe at the same time. Special Tool - Bearing Driver Set: 57001–1129 [A] •...
  • Page 329: Stem Bearing Lubrication

    14-8 STEERING Steering Stem • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 330: Handlebar

    STEERING 14-9 Handlebar Handlebar Removal • Remove: Handlebar Holder Plugs Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] • Remove the handlebar holder [F] and then pull out the handlebar.
  • Page 332 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-7 Rear Seat Removal......................15-7 Rear Seat Installation......................15-7 Front Seat Removal ......................15-7 Front Seat Installation ....................... 15-7 Side Covers ..........................15-8 Side Cover Removal ......................15-8 Side Cover Installation ...................... 15-8 Fairings...........................
  • Page 333: Exploded View

    15-2 FRAME Exploded View...
  • Page 334 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Footpeg bracket bolts 2 Side stand bracket bolts 3 Side stand bolt 4 Side stand switch bolt 0.90 78 in·lb G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 335 15-4 FRAME Exploded View...
  • Page 336 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front fender bracket bolts 0.90 78 in·lb Front fender bolts 0.40 35 in·lb...
  • Page 337 15-6 FRAME Exploded View...
  • Page 338: Seats

    FRAME 15-7 Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Rear Seat Installation • Slip the rear seat hooks [A] into the hollow-cubic bracket [B] on the frame.
  • Page 339: Side Covers

    15-8 FRAME Side Covers Side Cover Removal • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. • Install the bolt.
  • Page 340: Fairings

    FRAME 15-9 Fairings Inner Cover Removal • Remove: Inner Cover Screws [A] and Washers Inner Cover [B] Inner Cover Installation • Fit the projection [A] on the inner cover [B] into the hole [C] in the fairing. • Install the washers and inner cover screws. Fairing Removal •...
  • Page 341: Seat Covers

    15-10 FRAME Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick rivets [A]. • Pull the front portions [A] of the seat cover outside [B], and then remove the seat cover backward. Seat Cover Installation •...
  • Page 342: Mud Guard

    FRAME 15-11 Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter) Bolt [A] Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].
  • Page 343: Fenders

    15-12 FRAME Fenders Front Fender Removal • Remove: Front Wheel (see Wheels/Tires chapter) Brake Hose Clamps Front Reflector Bolts [A] Bolts [B] (both side) • Remove the front fender [C]. Front Fender Installation • Apply a non-permanent locking agent to the threads of the bracket bolts.
  • Page 344: Rear Fender Rear Installation

    FRAME 15-13 Fenders • Remove: Quick Rivets [A] Rear Fender Rear [B] Rear Fender Rear Installation • Put the projection [A] into the hole [B]. • Put the projections [A] into the holes [B]. • Installation is reverse of removal.
  • Page 345: Frame Cover

    15-14 FRAME Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side)
  • Page 346: Battery Case

    FRAME 15-15 Battery Case Battery Case Removal • Remove: Seats Seat Cover Rear Fender Assy Side Covers Battery Reserver Tank Screws • Pull out the battery case [A] backward. Battery Case Installation • Put the battery case attachments [A] at the projections [B] on the frame.
  • Page 347: Side Stand

    15-16 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation •...
  • Page 348: Rear View Mirrors

    FRAME 15-17 Rear View Mirrors Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re- move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] with a pair of span- ners.
  • Page 349: Frame Inspection

    15-18 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 350 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location......................... 16-3 Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Wiring Diagram (Canada)....................... 16-12 Wiring Diagram (Australia) ..................... 16-14 Wiring Diagram (Other than Canada, Australia and Malaysia)..........16-16 Wiring Diagram (Malaysia) .....................
  • Page 351 16-2 ELECTRICAL SYSTEM Spark Plug Installation ...................... 16-44 Spark Plug Inspection ....................... 16-44 Spark Plug Gap Inspection ....................16-44 Interlock Operation Inspection ..................16-45 IC Igniter Inspection ......................16-46 Electric Starter System ......................16-49 Starter Motor Removal...................... 16-49 Starter Motor Installation....................16-49 Starter Motor Disassembly....................
  • Page 352: Parts Location

    ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch 9. Water Temperature Sen- 17. ECU Fuse 2. Camshaft Position Sen- 18. Turn Signal Relay 10. Battery 19. Diode (Rectifier) 3. Radiator Fan Switch 11. Junction Box 20. ECU (Electronic Control 4.
  • Page 353: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 354 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Meter mounting screws 0.12 10 in·lb Tail/brake light mounting screws 0.12 10 in·lb License plate light mounting screws 0.12 10 in·lb Front brake light switch screw 0.10 9 in·lb Starter locknut switch screws –...
  • Page 355 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 356 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water temperature sensor Spark plugs 113 in·lb Alternator lead holding plate bolt 95 in·lb Starter motor mounting bolts 95 in·lb Stator coil bolts 95 in·lb Alternator rotor bolt Starter motor clutch bolts 104 in·lb Alternator cover bolts 95 in·lb...
  • Page 357 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 358 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Regulator/rectifier bolts 0.70 61 in·lb Fuel level sensor bolts 0.70 61 in·lb 0.90 78 in·lb Side stand switch bolt Neutral switch Speed sensor bolt 0.70 61 in·lb Speed sensor cover bolts 0.70 61 in·lb Regulator/rectifier bracket bolts...
  • Page 359: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery: Type Sealed Battery Capacity 12 V 8 Ah Voltage 12.6 V or more Charging System: Type Three-phase AC Alternator output voltage 42 V or more 0.3 ∼ 0.4 Ω Stator coil resistance Charging voltage 14.7 ±0.5 V (regulator/rectifier output voltage) Ignition System:...
  • Page 360: Special Tools And Sealant

    Flywheel & Pulley Holder : Harness Adapter : 57001–1343 57001–1542 Hand Tester : Rotor Holder : 57001–1394 57001–1543 Flywheel Puller, M38 × 1.5 : Spark Plug Wrench (Owner’s Tool) : 57001–1405 92110–1146 Lead Wire-Peak Voltage Adapter : Kawasaki Bond (Silicone Sealant) : 57001–1449 56019–120...
  • Page 361: Wiring Diagram (canada)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (Canada)
  • Page 362 ELECTRICAL SYSTEM 16-13 Wiring Diagram (Canada)
  • Page 363: Wiring Diagram (australia)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia)
  • Page 364 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia)
  • Page 365: Wiring Diagram (other Than Canada, Australia And Malaysia)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than Canada, Australia and Malaysia)
  • Page 366 ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than Canada, Australia and Malaysia)
  • Page 367: Wiring Diagram (malaysia)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
  • Page 368 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia)
  • Page 369: Precautions

    16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○...
  • Page 370 ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B]...
  • Page 371: Electrical Wiring

    16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 372: Battery

    ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Con- trol Unit). Never reverse the connections of the battery, this could damage the ECU.
  • Page 373 16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] sealing the filler ports [B] until just before use. • Check to see that there is no peeling, tears or holes in the seal sheet on the top of the battery. •...
  • Page 374: Initial Charge

    However, if a battery shows a terminal voltage of 12.6 V or more, using a digital voltmeter, after 10 minutes of filling, no initial charge is necessary. Kawasaki-recommended chargers: OptiMate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 375: Precautions

    16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping–up No topping–up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seat cap to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been dis-...
  • Page 376: Interchange

    ELECTRICAL SYSTEM 16-27 Battery Interchange The sealed battery can fully display its performance only when combined with the proper vehicle electric system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
  • Page 377 16-28 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery Terminal Voltage (V) [A] Charge Time (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do stan- dard charge later on.
  • Page 378: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019– 120 • Check that knock pins [B] are in place on the crankcase.
  • Page 379: Stator Coil Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 380 ELECTRICAL SYSTEM 16-31 Charging System • Install the starter gear [A]. • Again, clean the crankshaft tapered portion [B] and dry there. • Fit the woodruff key [C] securely in the slot in the crank- shaft before installing the alternator rotor. •...
  • Page 381: Alternator Inspection

    16-32 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to the shaft [A], and install it and starter idle gear [B]. • Install the alternator cover (see Alternator Cover Installa- tion). Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism.
  • Page 382: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-33 Charging System If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
  • Page 383 16-34 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test: ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
  • Page 384: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection • Check the battery condition (see Battery section). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seats (see Frame chapter). • Check that the ignition switch is turned off, and connect the hand tester [A] to the battery terminals [B].
  • Page 385 16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 4. Regulator/Rectifier 7. Main Fuse 30 A 2. To Starter Circuit Relay 5. Joint Connector C 8. Load 3. Alternator 6. Battery 12 V 8 Ah...
  • Page 386: Ignition System

    ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 387: Crankshaft Sensor Installation

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Install the clamps [A] direction as shown.
  • Page 388: Crankshaft Sensor Inspection

    ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Inspection • Remove: Right Frame Cover (see Frame chapter) Crankshaft Sensor Lead Connector [A] • Set the hand tester to the × 100 Ω range and connect (+) lead to the yellow/black lead and (–) lead to the black lead in the connector.
  • Page 389: Timing Rotor Removal

    16-40 ELECTRICAL SYSTEM Ignition System Timing Rotor Removal • Remove the crankshaft sensor cover (see Crankshaft Sensor Removal) • Remove the timing rotor [A]. ○ Holding the timing rotor with the flywheel & pulley holder [B] and remove the bolt [C]. Special Tool - Flywheel &...
  • Page 390: Camshaft Position Sensor Inspection

    ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Position Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) • Set the hand tester to the × 10 Ω range and connect it to the yellow and black leads in the connector.
  • Page 391: Stick Coil (ignition Coil Together With Spark Plug Cap) Removal

    16-42 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Removal • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the thermostat bracket bolt [A]. • Disconnect: Water Temperature Sensor Connector [B] Left Switch Housing Connector [C] ○...
  • Page 392: Stick Coil (ignition Coil Together With Spark Plug Cap) Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see this chapter). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○...
  • Page 393: Spark Plug Removal

    16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 394: Interlock Operation Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove: Seats (see Frame chapter) Junction Box (see this chapter) ○ Do not disconnect the connectors. 1st Check • Measure the terminal voltage of the G/BK lead in the junc- tion box connector [A] in accordance with the following procedure.
  • Page 395: Ic Igniter Inspection

    16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC Igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, Ignition System Troubleshooting chapter and Fuel System (DFI) chapter for ECU Inspection.
  • Page 396 ELECTRICAL SYSTEM 16-47 Ignition System...
  • Page 397 16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 9. Throttle Sensor 18. Main Fuse 30 A 2. Engine Stop Switch 10. Neutral Switch 19. Battery 12 V 8 Ah 3. Starter Button 11. Junction Box 20. ECU 4.
  • Page 398: Electric Starter System

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Slide back the rubber cap [A]. • Remove the starter motor terminal nut [B]. •...
  • Page 399: Starter Motor Assembly

    16-50 ELECTRICAL SYSTEM Electric Starter System ○ The brush plate [A] and brushes come off with the right -hand end cover [B]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate [C] from the right-hand end cover.
  • Page 400: Brush Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Align the line [A] marked on the yoke with the through bolt hole [B]. Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assembly [B] and the terminal bolt assembly [C].
  • Page 401: Brush Lead Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○ Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
  • Page 402 ELECTRICAL SYSTEM 16-53 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defec- tive.
  • Page 403: Lighting System

    16-54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a head- light relay in the junction box. In these models, the head- light does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 404: Headlight Removal/installation

    ELECTRICAL SYSTEM 16-55 Lighting System • Fit the projection [A] of the bulb in the hollow [B] of the headlight. • Install the hook [C]. • Fit the dust cover [A] with the arrow mark upward onto the bulb [B] firmly as shown. Good [C] Bad [D] Arrow Mark [E]...
  • Page 405: City Light Bulb Replacement (european Model)

    16-56 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement (European Model) • Remove the fairing (see Frame chapter). • Pull out the socket [A] together with the bulb. • Pull the bulb [A] out of the socket. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
  • Page 406 ELECTRICAL SYSTEM 16-57 Lighting System Headlight/Tail Light Circuit (CA, AS) Headlight/Tail Light Circuit (Other than CA, AS) AS: Australia 8. High Beam Indicator 15. Passing Button CA: Canada Light (LED) 16. Main Fuse 30 A 1. Ignition Switch 9. Joint Connector D 17.
  • Page 407: Turn Signal Light Bulb Replacement

    16-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit CA: Canada model 6. Front Left Turn Signal 15. Ignition Switch MY: Malaysia model Light 16. Rear Right Turn Signal 1. Joint Connector D 7. Joint Connector A Light 2. Meter Unit 8.
  • Page 408 ELECTRICAL SYSTEM 16-59 Lighting System • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 409: Turn Signal Relay Inspection

    16-60 ELECTRICAL SYSTEM Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. Turn Signal Relay Inspection • Remove: Seats (see Frame chapter) Upper Seat Cover (see Frame chapter) Turn Signal Relay [A]...
  • Page 410: Tail/brake Light (led) Installation

    ELECTRICAL SYSTEM 16-61 Lighting System • Unscrew the bolts [A]. • Unscrew the mounting screws [A]. • Remove the tail/brake light (LED) [B]. ○ Pull out the mount portion [C]. Tail/Brake Light (LED) Installation • Tighten the tail/brake light mounting screws. Torque - Tail/Brake Light Mounting Screws: 1.2 N·m (0.12 kgf·m, 10 in·lb)
  • Page 411: Radiator Fan System

    16-62 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Disconnect the lead connector [A] from the radiator fan switch. • Using an auxiliary wire [A], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the following.
  • Page 412 ELECTRICAL SYSTEM 16-63 Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 5. Meter Ground 9. Fan Fuse 15 A 2. Radiator Fan Switch 6. Frame Ground 10. Main Fuse 30 A 3. Joint Connector A 7. Joint Connector B 11.
  • Page 413: Meter, Gauge, Indicator Unit

    16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Fairing (see Frame chapter) • Slide the dust cover [A] and remove the wiring connector [B]. • Remove the meter unit by taking off the mounting screws [C] with the washers. CAUTION Place the meter or gauge so that the face is up.
  • Page 414: Electronic Combination Meter Unit Inspection

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A]. [1] Ignition [10] Battery (+) [2] Fuel Reserve Switch [11] Oil Pressure Warning [3] Unused Indicator Light (LED) [4] Fuel Level Sensor Ground (–) [5] Neutral Indicator Light [12] Speed Sensor Supply (LED) Ground (–)
  • Page 415 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit MODE AND RESET BUTTON Operation Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Check that the display change to the ODO, TRIP, and CLOCK displays each time the MODE button [A] is pressed.
  • Page 416 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the RESET button to effect the MINUTE setting mode. ○ The minute display flashes on the display. • Press the MODE button to set the minute. •...
  • Page 417 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel off the ground, using the jack. ○ Turn on the ignition switch. ○...
  • Page 418 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Water Temperature Meter Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Connect the variable rheostat [A] to the terminal [8] as shown.
  • Page 419 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Fuel Level Gauge Inspection: • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Connect a variable rheostat [A] to terminal [4] and [9] as shown.
  • Page 420 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit • If the oscillator is not available, the tachometer can be checked as follows. ○ Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check".
  • Page 421 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light: Battery Positive (+) Terminal to Terminal [15] •...
  • Page 422 ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indica- 8. Fuel Level Gauge 20. Water Temperature Sen- tor Light (LED) 9. Tachometer 2. High Beam Indicator 10. Speedometer 21. Oil Pressure Switch Light (LED) 11. Meter Light (LED) 22.
  • Page 423: Switches And Sensors

    16-74 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms).
  • Page 424: Water Temperature Sensor Inspection

    ELECTRICAL SYSTEM 16-75 Switches and Sensors • Remove the fan switch [A]. • Suspend the switch [A] in a container of coolant so that the temperature–sensing projection and threaded portion are submerged. • Suspend an accurate thermometer [B] in the coolant so that the sensitive portions are located in almost the same depth.
  • Page 425: Speed Sensor Inspection

    16-76 ELECTRICAL SYSTEM Switches and Sensors • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged. • Suspend an accurate thermometer [B] in the coolant. NOTE ○ The sensor and thermometer must not touch the con- tainer side or bottom.
  • Page 426 ELECTRICAL SYSTEM 16-77 Switches and Sensors • Remove: Bolts [A] Speed Sensor Cover • Remove: Bolt [A] • Take out the speed sensor [B]. • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. •...
  • Page 427: Fuel Level Sensor Inspection

    16-78 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Open the clamps [A]. • Remove: Bolts [B] Fuel Level Sensor [C] • Check that the float moves up and down smoothly without binding.
  • Page 428: Diode (rectifier) Inspection

    ELECTRICAL SYSTEM 16-79 Switches and Sensors • Connect the test light [A] (12 V 3.4 W bulb a socket with leads) and the 12 V battery [B] to the fuel level sensor connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) →...
  • Page 429: Junction Box

    16-80 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box [A]. •...
  • Page 430: Starter Circuit/headlight Relay Inspection

    ELECTRICAL SYSTEM 16-81 Junction Box Starter Circuit/Headlight Relay Inspection • Remove the junction box (see Junction Box Fuse Circuit Inspection). • Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown.
  • Page 431: Diode Circuit Inspection

    16-82 ELECTRICAL SYSTEM Junction Box Diode Circuit Inspection • Remove the junction box. • Check conductivity of the following pairs of terminals. Diode Circuit Inspection Tester 13-8, 13-9, 12-11, 12-14, 15-14, 16-14 Connection The resistance should be low in one direction and more than ten times as much in the other direction.
  • Page 432: Fuse

    ELECTRICAL SYSTEM 16-83 Fuse 30 A Main Fuse Removal • Remove: Right Side Cover (see Frame chapter) 30 A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal •...
  • Page 433: Fuse Inspection

    16-84 ELECTRICAL SYSTEM Fuse Fuse Inspection • Remove the fuse (see Fuse Removal). • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.
  • Page 434 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-18...
  • Page 435 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 436 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fixes by the left side clamp of the tank. 2. Run the tank drain hose under the bracket for the side cover. 3. Air cleaner drain hose 4. Cooling reserve tank hose (Run the hose inside the under ring.) 5.
  • Page 437 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 438 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch cable 37. To neutral Switch 2. Meter ground 38. To speed sensor 3. Clamp (Ignition switch connector) 39. Alternator 4. Ignition switch connector 40. Engine harness 5. Inlet air pressure sensor 41.
  • Page 439 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 440 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground 5. Engine harness 6. Water temperature sensor 7.
  • Page 441 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 442 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Tail light 2. Clamp 3. Atmospheric pressure sensor 4. To ECU fuse 5. Junction Box 6. To self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10.
  • Page 443 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 444 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp the position of branch harness and front right turn signal light lead. 2. Run the meter harness into the hole of cover. 3. Meter 4. Set the cover to cover all of the connector. 5.
  • Page 445 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 446 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Run the brake hose through the inside of the reservoir hose. 4. Tight the bolt to the specified torque with the stopper (for turning prevention) applied. 5. Seat lock 6.
  • Page 447 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 448 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Fan switch horn lead 3. Cap 4. Clutch cable (Run the cable through forward the water hose.) 5.
  • Page 449 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 450 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Install the lead upward. 4. Pickup coil and oil pressure switch (Run the cable through inner side from the starter lead.) 5.
  • Page 451: Troubleshooting Guide

    17-18 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 452 APPENDIX 17-19 Troubleshooting Guide Air cleaner duct loose Piston ring/groove clearance excessive Compression low: Cylinder head gasket damaged Spark plug loose Cylinder head warped Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn...
  • Page 453: Gear Shifting Faulty

    17-20 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Engine load faulty: Clutch slipping Doesn’t go into gear; shift pedal doesn’t Engine oil level too high return: Engine oil viscosity too high Clutch not disengaging Drive train trouble Shift fork bent or seized Brake dragging Gear stuck on the shaft Lubrication inadequate:...
  • Page 454: Exhaust Smokes Excessively

    APPENDIX 17-21 Troubleshooting Guide Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn White smoke: Air suction valve damaged Piston oil ring worn Vacuum switch valve damaged Cylinder worn...
  • Page 455: Battery Trouble

    17-22 APPENDIX Troubleshooting Guide Battery Trouble: Rear shock adjustment too soft Front fork, rear shock absorber spring weak Battery discharged: Rear shock absorber oil leaking Charge insufficient Battery faulty (too low terminal voltage) Brake Doesn’t Hold: Battery lead making poor contact Load excessive (e.g., bulb of excessive Air in the brake line wattage)
  • Page 456 MODEL APPLICATION Year Model Beginning Frame No. □ JKAZRDJ1 4A000001 2004 ZR750–J1 ZR750J–000001 JKAZR750JJA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1323-01 Printed in Japan...

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2004 zr750–j1

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