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VERSYS 1000
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki VERSYS 1000

   Summary of Contents for Kawasaki VERSYS 1000

  • Page 1 VERSYS 1000 Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6: Country And Area Codes

    LIST OF ABBREVIATIONS ampere(s) inch(s) ABDC after bottom dead center km/h kilometers per hour antilock brake system KTRC Kawasaki traction control system alternating current liter(s) ampere hour liquid crystal display ATDC after top dead center light emitting diode BBDC before bottom dead center...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13: General Information

    Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLZ1000AC (Europe) Left Side View KLZ1000AC (Europe) Right Side View Frame Number Engine Number...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KLZ1000AC Dimensions Overall Length 2 235 mm (87.99 in.) Overall Width 900 mm (35.4 in.) Overall Height/High Position 1 405 mm (55.31 in.)/1 430 mm (56.3 in.) Wheelbase 1 520 mm (59.84 in.) Road Clearance 155 mm (6.10 in.) Seat Height 845 mm (33.3 in.)
  • Page 19 GENERAL INFORMATION 1-9 General Specifications Items KLZ1000AC Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.627 (83/51) Clutch Type Wet multi disc...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items KLZ1000AC Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam High Beam 12 V 55 W Low Beam 12 V 55 W Tail/Brake Light Alternator: Type Three-phase AC Specifications are subject to change without notice, and may not apply to every country.
  • Page 21: Unit Conversion Table

    GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System (DFI)........................ 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............2-15 Idle Speed Inspection .......................
  • Page 24 2-2 PERIODIC MAINTENANCE Lights and Switches Operation Inspection................ 2-42 Headlight Aiming Inspection ..................... 2-44 Sidestand Switch Operation Inspection ................2-45 Engine Stop Switch Operation Inspection................. 2-46 Others ..........................2-47 Chassis Parts Lubrication ....................2-47 Bolts, Nuts and Fasteners Tightness Inspection............... 2-49 Replacement Parts ......................
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Drive chain wear - inspect # 2-32 •...
  • Page 27 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element # - replace Every 18 000 km (11 250 mile) 2-50 Fuel hose - replace 5 years...
  • Page 28: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AD: Apply adhesive (ThreeBond: TB1344N or equivalent). AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Throttle Body Assy Holder Bolts 106 in·lb Plugs 19.6 2.00 14.5 Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb Front Camshaft Chain Guide Bolt (Upper) Rear Camshaft Chain Guide Bolt Front Camshaft Chain Guide Bolt (Lower) 106 in·lb Coolant By-pass Fitting Bolt...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Middle Engine Mounting Nut Lower Engine Mounting Nut Lower Adjusting Collar Locknut Lower Adjusting Collar 87 in·lb Crankshaft/Transmission Balancer Shaft Clamp Bolt 87 in·lb Balancer Shaft Lever Bolt Breather Side Plate Bolt 0.60 52 in·lb...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Disc Mounting Bolts Front Brake Pad Spring Bolts 0.30 26 in·lb Bleed Valve 0.80 69 in·lb Front Caliper Assembly Bolts Front Brake Pad Pin Front Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb Carrier Bracket Bolts Carrier Mounting Bolts 0.90 78 in·lb Rear Frame Guard Bolts 0.90 78 in·lb Rear Footpeg Bracket Bolts (Lower) Rear Footpeg Bracket Nuts Electrical System Switch Housing Screws...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 34: Specifications

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 2 1/2 (for reference) –...
  • Page 35 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.6 in.) Length) Standard Chain: Make ENUMA – – – Type EK525RMX – – – Link 116 Links –...
  • Page 36: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001-143 57001-1262 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Pilot Screw Adjuster, A: Throttle Sensor Setting Adapter: 57001-1239 57001-1538 Oil Filter Wrench: Fuel Hose: 57001-1249 57001-1607...
  • Page 37: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage.
  • Page 38 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Connect a highly accurate tachometer [B] to one of the stick coil primary leads.
  • Page 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any vacuum is not within specifications, first synchro- nize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies. Example: #1: 260 mmHg #2: 300 mmHg #3: 250 mmHg #4: 280 mmHg •...
  • Page 40 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn in the bypass screw [A] with counting the number of turns until it seals fully but not tightly. Record the number of turns. NOTICE Do not over tighten them. They could be damaged, requiring replacement.
  • Page 41: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebars to both sides [A]. If handlebars movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged.
  • Page 42: Cooling System

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the hose joints are securely connected. ○ Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off.
  • Page 43: Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 44: Valve Clearance Adjustment

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ○ When positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 45 PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures ○ Besides the standard shims in the valve clearance adjust- ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment Shims Thickness 3.225 mm...
  • Page 46 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 47 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 48: Air Suction System Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 49: Clutch

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 50: Wheels/tires

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 51: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Tread Depth Standard: Front 4.4 mm (0.17 in.) Rear 6.6 mm (0.26 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) Up to 130 km/h (80 mph) 3 mm (0.12 in.) Over 130 km/h (80 mph) WARNING...
  • Page 52: Final Drive

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 53: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Chain Slack Adjustment • Raise the rear wheel off the ground with the stand. • Remove the cotter pin [A], and loosen the axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the right and left chain adjusters [D] evenly.
  • Page 54: Wheel Alignment Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they are not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 55: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspension chapter). • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage.
  • Page 56: Brakes

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) •...
  • Page 57: Brake Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) •...
  • Page 58: Brake Fluid Level Inspection

    2-36 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 handlebars when checking brake fluid level.
  • Page 59: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Brake Pad Wear Inspection • Remove the brake pads (see Front/Rear Brake Pad Re- moval in the Brakes chapter). • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.
  • Page 60: Suspension

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not go on, inspect or replace the following items. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (see Tail/Brake Light Removal in the Electri- cal System chapter) Main Fuse 30 A and Brake Light/HornFuse 10 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in...
  • Page 61: Rear Shock Absorber Oil Leak Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one. Rocker Arm Operation Inspection •...
  • Page 62: Steering Play Adjustment

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Play Adjustment • Remove: Upper Fairing Bracket (see Upper Fairing Bracket Re- moval in the Frame chapter) Handlebars and Lower Handlebar Holder (see Handle- bar Removal in the Steering chapter) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] Upper Front Fork Clamp Bolts [C] (Loosen) Stem Head [D]...
  • Page 63: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 64: Electrical System

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch to ON. • The following lights should go on according to below table. City Light [A] goes on Taillight [B]...
  • Page 65 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should blink. •...
  • Page 66: Headlight Aiming Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to blue high beam position. • The low beam [A] and high beam [B] headlights should go on. • The blue high beam indicator light (LED) [C] should go on. If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following item.
  • Page 67: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures NOTE ○ For CA model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.
  • Page 68: Engine Stop Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
  • Page 69: Others

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 70 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 71: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 72: Replacement Parts

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 73 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Be sure to place a piece of cloth around the fuel hose joint. • Insert a thin blade screwdriver [A] into the slit [B] on the joint lock [C]. • Turn the driver to disconnect the joint lock. •...
  • Page 74: Coolant Change

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts.
  • Page 75 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. NOTICE Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.
  • Page 76: Radiator Hose And O-ring Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Removal in the Cooling System chapter) Oil Cooler [C] (see Oil Cooler Removal in the Engine Lubrication System chapter)
  • Page 77: Engine Oil Change

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 78: Brake Hose Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Replacement • Remove: Brake Hose Fitting Bolt [A] NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. •...
  • Page 79 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • For the brake hoses of the ABS, note the following. NOTE ○ When removing the brake pipes and hoses on the hy- draulic unit, remove them according to each assembly of the exploded view in the Brakes chapter. •...
  • Page 80: Brake Fluid Change

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 81: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove: Reservoir Cap [A] Diaphragm Plate [B] Diaphragm [C] •...
  • Page 82: Caliper Rubber Parts Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Apply silicone grease to the contact portion of the push rod and brake lever pivot bolt.
  • Page 83 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valve [C] and rubber cap [D]. • Repeat the previous step to remove the pistons from the other side of the caliper body.
  • Page 84 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Disassembly • Remove: Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Rear Caliper (see Rear Caliper Removal in the Brakes chapter) • Remove the pad spring [A]. • Remove: Dust Boot [A] Sleeve [B] •...
  • Page 85: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • Replace the fluid seal [A] with a new one. ○ Apply silicone grease to the fluid seal, and install it into the cylinder by hand. • Replace the dust seal [B] with a new one. ○...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-16 Specifications ......................... 3-18 Special Tools and Sealant ...................... 3-20 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline ..........................
  • Page 88 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Installation ..................3-68 Vehicle-down Sensor Input Voltage Inspection..............3-69 Vehicle-down Sensor Output Voltage Inspection .............. 3-70 Subthrottle Sensor (Service Code 32)..................3-72 Subthrottle Sensor Removal/Adjustment ................3-72 Subthrottle Sensor Input Voltage Inspection..............3-72 Subthrottle Sensor Output Voltage Inspection ..............3-73 Subthrottle Sensor Resistance Inspection ................
  • Page 89 FUEL SYSTEM (DFI) 3-3 Fuel Pump ..........................3-104 Fuel Pump Removal ......................3-104 Fuel Pump Installation ...................... 3-105 Fuel Pump Operation Inspection ..................3-105 Fuel Pump Operating Voltage Inspection ................. 3-106 Pressure Regulator Removal.................... 3-106 Pump Screen, Fuel Filter Cleaning ................... 3-107 Fuel Pump Relay Removal/Installation ................
  • Page 90: Exploded View

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

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Upper Air Cleaner Housing Screws 0.11 10 in·lb Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb Throttle Body Assy Holder Bolts 106 in·lb Air Cleaner Duct Clamp Bolts 0.20...
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor Crankshaft Sensor Bolts 0.60 52 in·lb Intake Air Temperature Sensor Mounting 0.12 11 in·lb Screw Water Temperature Sensor 106 in·lb 5. Crankshaft Sensor 6. Intake Air Temperature Sensor 7.
  • Page 94 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 96: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 97 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Vehicle-down Sensor 4. Fuel Filter 5. Pressure Regulator 6. Fuel Pump 7. Fuel Flow 8. Delivery Pipe Assy 9. Intake Air Temperature Sensor 10. Subthrottle Sensor 11.
  • Page 98 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 99 FUEL SYSTEM (DFI) 3-13 DFI System Part Names 1. Joint Connector E 2. ECU 3. Joint Connector D 4. Rear Wheel Rotation Sensor 5. Joint Connector B 6. Frame Ground 2 7. Frame Ground 3 8. Frame Ground 1 9. Engine Ground 10.
  • Page 100 3-14 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green Terminal Numbers of ECU Connectors...
  • Page 101 60. External Communication Line (Immobilizer, Equipped Model/*KDS): GY/BL 61. Meter Unit (Tachometer): LB 62. Radiator Fan Relay: Y/BL 63. Air Switching Valve: R/BL 64. Oxygen Sensor Heater: P/BK 65. Ground for Ignition System: BK/Y 66. Stick Coil #3: BK/O *: KDS (Kawasaki Diagnostic System)
  • Page 102: Dfi Parts Location

    3-16 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Crankshaft Sensor [A] Oxygen Sensor [B] Ignition Key (Transponder, Equipped Model) [A] Ignition Switch [B] Immobilizer Antenna [C] (Equipped Model) Red Warning Indicator Light (LED) [D] Stick Coils [A] Air Switching Valve [B] Intake Air Pressure Sensor #1 [C]...
  • Page 103 Battery 12 V 8 Ah [A] ECU Fuse 15 A [B] Relay Box (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) [C] ECU [D] Immobilizer (Equipped Model)/Kawasaki Diagnostic System Connector [E] Fuel Pump [A] Rear Wheel Rotation Sensor [A]...
  • Page 104: Specifications

    3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.42 in.) Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) Bypass Screws (Turn Out) 2 1/2 (for reference) ECU:...
  • Page 105 FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 1.08 ∼ 1.12 V at subthrottle valve full close Output Voltage position DC 4.2 ∼ 4.4 V at subthrottle valve full open position (for reference) 4 ∼...
  • Page 106: Special Tools And Sealant

    3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Carburetor Drain Plug Wrench, Hex 3: Needle Adapter Set: 57001-1269 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Vacuum Gauge: Fuel Pressure Gauge Adapter: 57001-1369 57001-1593...
  • Page 107 FUEL SYSTEM (DFI) 3-21 Special Tools and Sealant Measuring Adapter: Liquid Gasket, TB1211: 57001-1700 56019-120...
  • Page 108: Dfi Servicing Precautions

    3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ 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 109 FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 110: Troubleshooting The Dfi System

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System The red warning indicator light (LED) [A] is used for the immobilizer indicator (equipped model), battery warning in- dicator, oil pressure warning indicator and water tempera- ture warning indicator. Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on to alert the rider.
  • Page 111 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solv- ing unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 112 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. ○ The DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
  • Page 113 FUEL SYSTEM (DFI) 3-27 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 114: Inquiries To Rider

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 115 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 116 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 117: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 118 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3).
  • Page 119 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3).
  • Page 120: Poor Running Or No Power At High Speed

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter)
  • Page 121 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Rear wheel rotation sensor trouble Inspect (see chapter 12).
  • Page 122: Self-diagnosis

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system, igni- tion system and immobilizer system by goes on or blinking the yellow engine warning indicator light (LED) [A] or red warning indicator light (LED) [B] and immobilizer warning symbol [C] when DFI, ignition and immobilizer system parts...
  • Page 123: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the yellow engine warning indicator light (LED) [A] goes on. ○ When a problem occurs with KTRC system, the yellow KTRC warning indicator light (LED) [B] goes on, the KTRC and POWER mode symbols [C] blinking on the LCD.
  • Page 124 3-38 FUEL SYSTEM (DFI) Self-Diagnosis • Any of the following procedures ends self-diagnosis. ○ When the service code is displayed on the LCD, push the upper button for more than two seconds. ○ When the ignition switch is turned OFF. Self-Diagnosis Flow Chart...
  • Page 125: Service Code Reading

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the num- ber of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or- der.
  • Page 126 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code System Problems FI/KTRC Main throttle sensor malfunction, wiring open or short FI/KTRC Intake air pressure sensor #1 malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Intake air pressure sensor #2 malfunction, wiring open or short FI/KTRC...
  • Page 127: Backups

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, Main Throttle...
  • Page 128 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Immobilizer Amplifier If the immobilizer system fails (no signal, wiring – (Equipped short or open), the vehicle is no start and run. Model) Ignition Key The ignition key must use If the blank key or broken key is used, the...
  • Page 129 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Note: (1) D-J Method: The DFI control method from medium to heavy engine load. When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (intake air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage).
  • Page 130: Main Throttle Sensor (service Code 11)

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 131: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 132 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Turn the ignition switch to OFF. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch to ON. Output Voltage DC 1.02 ∼...
  • Page 133: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Resistance Inspection • Turn the ignition switch to OFF. • Disconnect the main throttle sensor connector. ○ Disconnect the main throttle sensor connector and con- nect the throttle sensor setting adapter [A] to the sensor connector only.
  • Page 134: Intake Air Pressure Sensor #1 (service Code 12)

    3-48 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Removal NOTICE Never drop the intake air pressure sensor #1 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 135: Intake Air Pressure Sensor #1 Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-49 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 136: Intake Air Pressure Sensor #1 Output Voltage Inspection

    3-50 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following.
  • Page 137 FUEL SYSTEM (DFI) 3-51 Intake Air Pressure Sensor #1 (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor #1 [A] and discon- nect the vacuum hose from the sensor. •...
  • Page 138 3-52 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
  • Page 139 FUEL SYSTEM (DFI) 3-53 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Circuit 1. ECU 2. Intake Air Pressure Sensor #1...
  • Page 140: Intake Air Temperature Sensor (service Code 13)

    3-54 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 141: Intake Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Intake Air Temperature Sensor (Service Code 13) • Turn the ignition switch to OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 142 3-56 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor...
  • Page 143: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-57 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 144: Water Temperature Sensor Resistance Inspection

    3-58 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) • Turn the ignition switch to OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 145: Intake Air Pressure Sensor #2 (service Code 16)

    FUEL SYSTEM (DFI) 3-59 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Removal NOTICE Never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 146: Intake Air Pressure Sensor #2 Input Voltage Inspection

    3-60 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 147: Intake Air Pressure Sensor #2 Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-61 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following.
  • Page 148 3-62 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Circuit 1. ECU 2. Intake Air Pressure Sensor #2...
  • Page 149: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-63 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 150: Rear Wheel Rotation Sensor Signal (service Code 24)

    3-64 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor Signal (Service Code 24) Rear Wheel Rotation Sensor Signal Inspection ○ The rear wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit. ○ The ECU uses the rear wheel rotation sensor signal for motorcycle speed and KTRC control.
  • Page 151 FUEL SYSTEM (DFI) 3-65 Rear Wheel Rotation Sensor Signal (Service Code 24) Rear Wheel Rotation Sensor Circuit 1. ECU 2. Rear Wheel Rotation Sensor 3. ABS Hydraulic Unit...
  • Page 152: Front Wheel Rotation Sensor Signal (service Code 27)

    3-66 FUEL SYSTEM (DFI) Front Wheel Rotation Sensor Signal (Service Code 27) Front Wheel Rotation Sensor Signal Inspection ○ The front wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit. ○ The ECU uses the wheel rotation sensor signal for KTRC control.
  • Page 153 FUEL SYSTEM (DFI) 3-67 Front Wheel Rotation Sensor Signal (Service Code 27) Front Wheel Rotation Sensor Circuit 1. ECU 2. ABS Hydraulic Unit 3. Front Wheel Rotation Sensor...
  • Page 154: Vehicle-down Sensor (service Code 31)

    3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 155: Vehicle-down Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Vehicle-down Sensor (Service Code 31) • The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situ- ations for an accident resulting in injury or death.
  • Page 156: Vehicle-down Sensor Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). • Connect the measuring adapter [A] to the vehicle-down sensor connectors as shown. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C] •...
  • Page 157 FUEL SYSTEM (DFI) 3-71 Vehicle-down Sensor (Service Code 31) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] Y/G lead (ECU terminal 19) [C] G lead (ECU terminal 49) [D]...
  • Page 158: Subthrottle Sensor (service Code 32)

    3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 159: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL lead (ECU terminal 4) [C] G lead (ECU terminal 49) [D]...
  • Page 160 3-74 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Remove the left side cover (see Side Cover Removal in the Frame chapter). • Turn the ignition switch to ON. •...
  • Page 161: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-75 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch to OFF. • Remove the right side cover (see Side Cover Removal in the Frame chapter). • Disconnect the subthrottle sensor connector. ○...
  • Page 162: Oxygen Sensor - Not Activated (service Code 33)

    3-76 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 163 FUEL SYSTEM (DFI) 3-77 Oxygen Sensor - not activated (Service Code 33) • Separate the air switching valve hoses [A] from the air suction valve covers. • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. •...
  • Page 164 3-78 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 165: Immobilizer Amplifier (service Code 35, Equipped Model)

    FUEL SYSTEM (DFI) 3-79 Immobilizer Amplifier (Service Code 35, Equipped Model) Antenna Resistance Inspection • Turn the ignition switch to OFF. • Remove the left upper side fairing (see Upper Side Fairing Removal in the Frame chapter). • Slide the rubber cover [A] and disconnect the antenna lead connector [B].
  • Page 166: Blank Key Detection (service Code 36, Equipped Model)

    7. Battery 12 V 8 Ah 13. Fuse Box 1 2. ECU 8. Starter Relay 14. Ignition Fuse 15 A 3. Immobilizer/Kawasaki Diag- 9. Main Fuse 30 A 15. Joint Connector F 10. ECU Fuse 15 A 16. Immobilizer Antenna nostic System Connector 4.
  • Page 167: Ecu Communication Error (service Code 39)

    FUEL SYSTEM (DFI) 3-81 ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 168: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)

    3-82 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation •...
  • Page 169 FUEL SYSTEM (DFI) 3-83 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch to OFF. If the input voltage is out of the standard, check the wiring for continuity (see Stick Coil Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 170: Radiator Fan Relay (service Code 56)

    3-84 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 171: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-85 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 172: Subthrottle Valve Actuator Input Voltage Inspection

    3-86 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these con- nectors as shown in the figure.
  • Page 173 FUEL SYSTEM (DFI) 3-87 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 174: Air Switching Valve (service Code 64)

    3-88 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 175: Oxygen Sensor Heater (service Code 67)

    FUEL SYSTEM (DFI) 3-89 Oxygen Sensor Heater (Service Code 67) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 176 3-90 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) • Disconnect the oxygen sensor lead connector and con- nect the measuring adapter [A] between these connec- tors. [B] Main Harness [C] Oxygen Sensor Special Tool - Measuring Adapter: 57001-1700 •...
  • Page 177 FUEL SYSTEM (DFI) 3-91 Oxygen Sensor Heater (Service Code 67) Oxygen Sensor Circuit 1. ECU 2. Frame Ground 3 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. ECU Fuse 15 A 8.
  • Page 178: Oxygen Sensor - Incorrect Output Voltage (service Code 94)

    3-92 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 179 FUEL SYSTEM (DFI) 3-93 Oxygen Sensor - Incorrect Output Voltage (Service Code 94) • Separate the air switching valve hoses [A] from the air suction valve covers. • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air.
  • Page 180 3-94 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), check the following. Fuel Pressure (see Fuel Pressure Inspection) Fuel Injector (see Fuel Injectors section) If the fuel pressure and fuel injectors are good, replace the sensor.
  • Page 181: Warning Indicator Light (led)

    FUEL SYSTEM (DFI) 3-95 Warning Indicator Light (LED) Yellow Engine Warning/Yellow KTRC Warning/Red Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light [A] Yellow KTRC Warning Indicator Light [B] Red Warning Indicator Light [C] • Refer to the Meter Unit Inspection in the Electrical System chapter for the warning indicator light (LED) inspection.
  • Page 182: Ecu

    3-96 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 183: Ecu Installation

    NOTICE Do not pinch the leads. • For WVTA (78.2 H) and GB WVTA (FULL H) Models, tighten the new screws [C] using the Kawasaki genuine screws of which threads are coated with locking agent. ECU Power Supply Inspection •...
  • Page 184 3-98 FUEL SYSTEM (DFI) If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU and relay box connectors. • Connect a digital meter [A] to the connectors [B] with the needle adapter set.
  • Page 185 FUEL SYSTEM (DFI) 3-99 ECU Power Source Circuit 1. Joint Connector E 2. ECU 3. Joint Connector D 4. Frame Ground 2 5. Frame Ground 3 6. Engine Ground 7. Battery 12 V 8 Ah 8. Starter Relay 9. Main Fuse 30 A 10.
  • Page 186: Dfi Power Source

    3-100 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 187: Fuel Line

    FUEL SYSTEM (DFI) 3-101 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) • Support the fuel tank with a suitable bar (see Fuel Tank Removal).
  • Page 188: Fuel Flow Rate Inspection

    3-102 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 189 FUEL SYSTEM (DFI) 3-103 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
  • Page 190: Fuel Pump

    3-104 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 191: Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-105 Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. • Check that the fuel pump terminal [A] and band [B] are in place.
  • Page 192: Fuel Pump Operating Voltage Inspection

    3-106 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the front seat (see Front Seat Removal in the Frame chapter). •...
  • Page 193: Pump Screen, Fuel Filter Cleaning

    FUEL SYSTEM (DFI) 3-107 Fuel Pump Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the pump and can not be cleaned or checked. If the pump screen or fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.
  • Page 194 3-108 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Joint Connector D 3. Frame Ground 2 4. Frame Ground 3 5. Engine Ground 6. Battery 12 V 8 Ah 7. Starter Relay 8. Main Fuse 30 A 9.
  • Page 195: Fuel Injectors

    FUEL SYSTEM (DFI) 3-109 Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Remove the left side cover (see Side Cover Removal in the Frame chapter).
  • Page 196: Fuel Injector Power Source Voltage Inspection

    3-110 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Turn the ignition switch to OFF. • Disconnect the injector connector and connect the mea- suring adapter [A] between these connectors as shown.
  • Page 197: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-111 Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. ○...
  • Page 198: Fuel Injector Fuel Line Inspection

    3-112 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 199 FUEL SYSTEM (DFI) 3-113 Fuel Injectors Fuel Injector Circuit 1. ECU 10. Relay Box 2. Joint Connector D 11. Fuel Pump Relay 12. ECU Main Relay 3. Frame Ground 2 4. Frame Ground 3 13. Fuse Box 1 14. Ignition Fuse 15 A 5.
  • Page 200: Throttle Grip And Cables

    3-114 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 201: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-115 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the...
  • Page 202 3-116 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen the locknuts [A]. • Turn the adjusters [B] to give the more free play. • Remove: Throttle Cable Holder Clamp [A] Throttle Cable Lower Ends [B] • Loosen the throttle body assy holder clamp bolts [A]. Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269...
  • Page 203: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-117 Throttle Body Assy • Remove the throttle body assy [A] from the throttle body assy holders. • Disconnect the injector connectors [B]. • Remove the clamps [C]. • After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.
  • Page 204: Throttle Body Assy Disassembly

    3-118 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Fuel Injectors 6. Delivery Pipe Assy NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...
  • Page 205: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-119 Throttle Body Assy • Pull out the fuel injectors [A] from the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the primary fuel injector, especially on a hard surface.
  • Page 206: Air Cleaner

    3-120 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 207: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-121 Air Cleaner • Loosen the air cleaner duct clamp bolt [A] (both sides). • Lift up the air cleaner housing, and remove the air switch- ing valve hose [B]. • After removing the air cleaner housing, cover the clean cloth on the throttle body assy.
  • Page 208: Fuel Tank

    3-122 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 209 FUEL SYSTEM (DFI) 3-123 Fuel Tank • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. •...
  • Page 210: Fuel Tank Installation

    3-124 FUEL SYSTEM (DFI) Fuel Tank • Pull [A] the fuel hose joint [B] out of the outlet pipe. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 211 FUEL SYSTEM (DFI) 3-125 Fuel Tank • Install the breather hose [A] and clamp securely. • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. •...
  • Page 212: Fuel Tank And Cap Inspection

    3-126 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Open the tank cap. • Visually inspect the gasket [A] on the tank cap for any damage. Replace the tank cap if gasket is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged.
  • Page 213 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 214: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 215 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator (Water) Hose Clamp Screws 0.30 26 in·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Thermostat Housing Bolts 0.60 52 in·lb Water Pipe Bolts 106 in·lb Water Pump Impeller Bolt 87 in·lb Water Pump Cover Bolts 97 in·lb...
  • Page 216: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator Cap 9. Outlet Pipe 2. Radiator Fan 10. Water Temperature Sensor 3. Radiator 11. Thermostat Housing 4. Oil Cooler 12. Reserve Tank Overflow Hose 5. Cylinder Head Jacket 13. Reserve Tank 6. Cylinder Jacket 14.
  • Page 217 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro- sion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 218: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 219: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver 37.5: 57001-1129 57001-1660...
  • Page 220: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 221: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 222: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter)
  • Page 223 COOLING SYSTEM 4-11 Water Pump • Be sure to install the dowel pins [A]. • Install: Water Pump Housing [A] Water Pump Impeller [B] • Tighten: Torque - Water Pump Impeller Bolt [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Be sure to install the dowel pins [D].
  • Page 224: Water Pump Inspection

    4-12 COOLING SYSTEM Water Pump • Apply a non-parmanent locking agent to the threads of the water pipe bolts [A], and tighten them. Torque - Water Pipe Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Connect the water hose [B] to the upper water pipe. •...
  • Page 225: Water Pump Housing Disassembly

    COOLING SYSTEM 4-13 Water Pump Water Pump Housing Disassembly NOTICE Do not damage the hole wall of the water pump housing. • Insert a bar [A] into the pump housing [B], and hammer evenly around the circumference of the mechanical seal bottom [C].
  • Page 226: Radiator

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove the middle fairing (see Middle Fairing Removal in the Frame chapter). • Remove the side cover (see Side Cover Removal in the Frame chapter). • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 227: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-15 Radiator • Move the radiator [A] rightward to clear it from the frame projection [B]. • Clear the heat insulation rubber plate [C] from the radiator upper mounting brackets [D] and fan motor bracket. • Remove the radiator from the frame. NOTICE Do not touch the radiator core.
  • Page 228: Radiator Inspection

    4-16 COOLING SYSTEM Radiator • Fit the slits on the heat insulation rubber plate [A] to the upper mounting brackets [B] and fan motor bracket [C]. • Insert the upper right mounting bracket to the frame pro- jection [D]. • Make sure the throttle and clutch cables are routed cor- rectly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 229: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-17 Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
  • Page 230: Thermostat

    4-18 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Harness Holder [A] Water Hose Clamp [B] Water Hose [C] Water Pipe Bolts [D] Water Pipe [E] •...
  • Page 231: Thermostat Inspection

    COOLING SYSTEM 4-19 Thermostat • Replace the O-ring [A] with a new one. • Apply grease to the O-ring, and install it. • Install the thermostat housing cover [B]. NOTE ○ Note that the thermostat does not move at the place when installing the thermostat housing cover.
  • Page 232: Hose And Pipes

    4-20 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 233: Water Temperature Sensor

    COOLING SYSTEM 4-21 Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 235 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Warp Inspection ... 5-28 Exhaust System Identification ... Valves ..........5-29 Specifications ........Valve Clearance Inspection ..5-29 Special Tools and Sealant ....5-10 Valve Clearance Adjustment..5-29 Clean Air System.......
  • Page 236: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 237 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Spark Plugs 115 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Sprocket Bolts Upper Camshaft Chain Guide Bolts 106 in·lb Camshaft Cap Bolts 106 in·lb Cylinder Head Bolts (M10) (First) S, MO...
  • Page 238 5-4 ENGINE TOP END Exploded View...
  • Page 239 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolt Premuffler Chamber Mounting Bolt Muffler Body Clamp Bolt Muffler Body End Cover Bolts 87 in·lb Premuffler Chamber Guard Bolts 87 in·lb R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 240: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Muffler Body Mark Position [A]...
  • Page 241 ENGINE TOP END 5-7 Exhaust System Identification Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Positions [A]...
  • Page 242: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 32.943 ∼ 33.057 mm (1.2970 ∼ 1.3015 in.) Exhaust 32.84 mm (1.293 in.) 32.943 ∼ 33.057 mm (1.2970 ∼ 1.3015 in.) Intake 32.84 mm (1.293 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 243 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Cylinder, Pistons 76.990 ∼ 77.006 mm (3.0311 ∼ 3.0317 in.) Cylinder Inside Diameter 77.09 mm (3.035 in.) 76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) Piston Diameter 76.82 mm (3.024 in.) 0.010 ∼...
  • Page 244: Special Tools And Sealant

    5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 28: 57001-221 57001-1119 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Piston Pin Puller Assembly: Valve Seat Cutter, 32° - 33: 57001-910 57001-1199 Valve Seat Cutter, 45°...
  • Page 245 ENGINE TOP END 5-11 Special Tools and Sealant Valve Guide Reamer, 4.5: Valve Spring Compressor Adapter, 24: 57001-1333 57001-1586 Valve Seat Cutter, 60° - 33: Compression Gauge Adapter, M10 × 1.0: 57001-1334 57001-1601 Valve Seat Cutter, 60° - 27: L-Shape Hose: 57001-1409 57001-1606 Engine Mount Nut Wrench:...
  • Page 246: Clean Air System

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal) Stick Coil Connector (see Stick Coil Removal in the Elec- trical System chapter) Connector [A] (from Bracket [B] at Left Side) Air Suction Valve Cover Bolts [C] and Bracket...
  • Page 247: Air Suction Valve Inspection

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 248: Air Switching Valve Unit Test

    5-14 ENGINE TOP END Clean Air System Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers.
  • Page 249: Cylinder Head Cover

    ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Side Cover (see Side Cover Removal in the Frame chap- ter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Remove: Radiator Cap Mounting Bolt [A] and Collar •...
  • Page 250 5-16 ENGINE TOP END Cylinder Head Cover • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the cylinder head as shown. Sealant - Liquid Gasket, TB1216B: 92104-1064 •...
  • Page 251 ENGINE TOP END 5-17 Cylinder Head Cover • Install: Air Suction Valves [A] (see Air Suction Valve Installation) Air Switching Valve [B] (see Air Switching Valve Installa- tion) Hoses [C] • Position the rubber cover on the cylinder head cover. •...
  • Page 252: Camshaft Chain Tensioner

    5-18 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
  • Page 253: Camshaft, Camshaft Chain

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Turn the crankshaft clockwise, align the #1, 4 mark on the timing rotor with the crankcase timing mark.
  • Page 254: Camshaft Installation

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] NOTE ○ The exhaust camshaft has a 1169 EX mark [A] and the intake camshaft has a 1169 IN mark [B]. Be careful not to mix up these shafts.
  • Page 255 ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown in the figure.
  • Page 256 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tem- porarily (see Camshaft Chain Tensioner Installation). • Install the camshaft caps and upper camshaft chain guide [A] as shown in the figure.
  • Page 257: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Upper Chain Guide (see Camshaft Removal) Camshaft Caps (see Camshaft Removal) • Cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 258: Cam Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshafts (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: 32.943 ∼...
  • Page 259: Cylinder Head

    ENGINE TOP END 5-25 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)
  • Page 260: Cylinder Head Removal

    5-26 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) •...
  • Page 261 ENGINE TOP END 5-27 Cylinder Head • Replace the cylinder head gasket [A] with a new one. • Install the dowel pins [B] and cylinder head gasket. • Replace the cylinder head bolt washers [A] with new ones. • Apply molybdenum disulfide oil solution to both sides [B] of the cylinder head bolt washers and threads [C] of the bolts.
  • Page 262: Cylinder Head Warp Inspection

    5-28 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] ○ Apply grease to the new O-ring. • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 263: Valves

    ENGINE TOP END 5-29 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○...
  • Page 264: Valve Guide Installation

    5-30 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). NOTICE Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 265: Valve-to-guide Clearance Measurement (wobble Method)

    ENGINE TOP END 5-31 Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 266: Valve Seat Repair

    5-32 ENGINE TOP END Valves Valve Seat Repair • Repair the valve seat with the valve seat cutters [A]. Special Tools - Valve Seat Cutter Holder Bar [B]: 57001 -1128 Valve Seat Cutter Holder, 4.5 [C]: 57001 -1330 [For Exhaust Valve Seat] Valve Seat Cutter, 45°...
  • Page 267 ENGINE TOP END 5-33 Valves Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 268 5-34 ENGINE TOP END Valves If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low.
  • Page 269 ENGINE TOP END 5-35 Valves • Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 270 5-36 ENGINE TOP END Valves...
  • Page 271: Cylinder, Pistons

    ENGINE TOP END 5-37 Cylinder, Pistons Cylinder Removal • Remove: Radiator [A] (see Radiator and Radiator Fan Removal in the Cooling System chapter) Radiator Bracket [B] Cylinder Head [C] (see Cylinder Head Removal) Upper Engine Bracket (see Engine Removal in the En- gine Removal/Installation chapter) •...
  • Page 272: Piston Removal

    5-38 ENGINE TOP END Cylinder, Pistons • The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Upper Oil Ring Steel Rail [C]...
  • Page 273: Piston Installation

    ENGINE TOP END 5-39 Cylinder, Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. •...
  • Page 274: Piston Wear Inspection

    5-40 ENGINE TOP END Cylinder, Pistons Piston Wear Inspection • Measure the outside diameter [A] of each piston 11 mm (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton.
  • Page 275: Piston Ring Thickness Inspection

    ENGINE TOP END 5-41 Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Top [A] 0.77 ∼...
  • Page 276: Throttle Body Assy Holder

    5-42 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 277: Muffler

    ENGINE TOP END 5-43 Muffler WARNING The exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Muffler Body Removal •...
  • Page 278: Muffler Body Installation

    5-44 ENGINE TOP END Muffler Muffler Body Installation • Replace the muffler body gaskets [A] with new ones. • Install the muffler body gaskets until it is bottomed so that the inside chamfer side faces rear [B]. • Install the muffler body clamp [C] so that the insert the projection [D] into the clamp slit [E].
  • Page 279: Exhaust Pipe Removal

    ENGINE TOP END 5-45 Muffler Exhaust Pipe Removal • Remove: Muffler Body (see Muffler Body Removal) Oxygen Sensor (see Oxygen Sensor Removal in the Electrical System chapter) • Support the premuffler chamber with the suitable stand. • Loosen the premuffler chamber mounting bolt [A]. •...
  • Page 281 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 282: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 283 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Assembly Clamp Bolts 0.80 69 in·lb Clutch Cover Bolts 87 in·lb Oil Filler Plug – – – Hand-tighten Clutch Spring Bolts 0.92 80 in·lb Clutch Hub Nut 13.8 CL: Apply cable lubricant.
  • Page 284: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.) Clutch Plate Assembly Length – – – 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 285: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 286: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 287: Clutch Cover

    CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cable Lower End Clutch Cover Mounting Bolts [A] •...
  • Page 288: Release Shaft Installation

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 289: Clutch Cover Assembly

    CLUTCH 6-9 Clutch Cover Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Install the needle bearings [A] and oil seal [B] position as shown in the figure.
  • Page 290: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with Washer, Needle Bearing and Pusher [C]) • Remove: Friction Plates and Steel Plates Spring and Spring Seat NOTE ○...
  • Page 291 CLUTCH 6-11 Clutch • Install the clutch housing [A] to the drive shaft. • While holding the clutch housing, install the needle bear- ing [B] and sleeve [C]. ○ The holes [D] of the sleeve face outward. • Install the following parts to the drive shaft. Spacer ( 47 ×...
  • Page 292 6-12 CLUTCH Clutch • Install the friction plates and steel plates, starting with a friction plate and alternating them. NOTE ○ Install the both ends marked two friction plates at dis- assembled to the their original position. ○ When replace the friction plates with new ones, mark the both ends two friction plates so that the two kinds of friction plates do not mix up at opening the package.
  • Page 293: Clutch Plate Assembly Inspection

    CLUTCH 6-13 Clutch Clutch Plate Assembly Inspection • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Measure the length [A] of the clutch plate assembly as shown in the figure. ○ Assemble: Clutch Hub [B] Spring Seat [C] Spring [D] Friction Plates [E] Steel Plates [F]...
  • Page 294: Clutch Plate, Wear, Damage Inspection

    6-14 CLUTCH 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 295 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealants ....................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 296: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 297 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Plug – – – Hand-tighten Oil Cooler Bolts 106 in·lb Oil Passage Plugs Radiator (Water) Hose Clamp Screws 0.31 27 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.20 18 in·lb Oil Pressure Relief Valve...
  • Page 298: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Balancer Oil Passage 9. Oil Pressure Relief Valve 2. Camshaft Oil Passage 10. Oil Cooler 3. Crankshaft Oil Passage 11. Oil Filter 4. Drive Shaft Oil Passage 12. Main Oil Passage 5.
  • Page 299: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.2 L (3.4 US gt) (when filter is not removed) 3.8 L (4.0 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is completely dry) Level Between upper and lower level lines (Wait several minutes after...
  • Page 300: Special Tools And Sealants

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealants Liquid Gasket, TB1211: Oil Pressure Gauge Adapter, PT3/8: 56019-120 57001-1233 Outside Circlip Pliers: Liquid Gasket, TB1207B: 57001-144 92104-2068 Oil Pressure Gauge, 10 kgf/cm²: 57001-164...
  • Page 301: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 302: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter [A] (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan Bolts [B] Oil Pan [C] •...
  • Page 303 ENGINE LUBRICATION SYSTEM 7-9 Oil Pan NOTE ○ Make the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is ap- plied. ○ Moreover fit the oil pan and tighten the bolts just after application of the liquid gasket.
  • Page 304: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation • Clean the oil screen (see Oil Screen Cleaning). • Replace the O-ring [A] with a new one, and install it. •...
  • Page 305: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Screen (see Oil Screen Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-parmanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 306: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) • Pull the water pump shaft [A] to remove the oil pump cover [B]. • Remove: Oil (Water) Pump Shaft [A] with Inner Rotor [B] Outer Rotor [C] Oil Pump Installation •...
  • Page 307: Oil Pump Drive Gear Removal

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pan (see Oil Pan Removal) Circlip [A] and Washer [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Oil Pump Drive Gear [A] Washer [B]...
  • Page 308: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Left Lower Fairing Assembly (see Lower Fairing Assem- bly Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Water Hose Clamp Screws (Loosen) [A] Water Hoses [B]...
  • Page 309: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Remove the oil passage plug [A]. • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233...
  • Page 310: Oil Pressure Switch

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Left Lower Fairing Assembly (see Lower Fairing Assem- bly Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation...
  • Page 311: Oil Pipe

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pipe Oil Pipe Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe [A] Oil Pipe Installation • Replace the O-rings [A] with new ones. • Apply grease to the O-rings, and install them.
  • Page 313 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 314: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 315 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Bracket Bolts (M10) Upper Engine Bracket Bolt (M8) Lower Engine Bracket Bolts Upper Adjusting Collar 87 in·lb Upper Engine Mounting Bolt (L = 65) Upper Adjusting Collar Locknut Upper Engine Mounting Bolt (L = 54) Rear Engine Bracket Bolts Middle Engine Bracket Bolts...
  • Page 316: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 317: 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 Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 318 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Engine Ground Cable Terminal Bolt [A] Engine Sprocket [B] (see Engine Sprocket Removal in the Final Drive chapter) • Remove the drive chain from the output shaft. • Remove Left Lower Fairing Stay [A] Right Lower Fairing Stay [B] •...
  • Page 319: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Upper Engine Mounting Bolt [A] (Both Sides) Middle Engine Mounting Nut [B], Bolt and Collar Lower Engine Mounting Nut [C] • Using the nut wrench [A], loosen the upper adjusting collar locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 •...
  • Page 320 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Insert the lower engine mounting bolt [A] from the left. • Insert the middle engine mounting bolt [B] from the left, placing the collar [C] between the engine and frame. • Install and tighten the left upper engine mounting bolts (L = 54) [A].
  • Page 321 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Install the left engine bracket [A] and tighten the mounting bolts evenly. Torque - Upper Engine Bracket Bolts (10 mm) [B]: 59 N·m (6.0 kgf·m, 44 ft·lb) Lower Engine Bracket Bolts [C]: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Engine Bracket Bolts [D]: 59 N·m (6.0 kgf·m, 44 ft·lb)
  • Page 322 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Fill the engine with coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 323 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Disassembly 9-27 Specifications ........Starter Motor Clutch Assembly ..9-27 Special Tools and Sealants ....External Shift Mechanism....9-28 Crankcase Splitting......Shift Pedal Removal ....9-28 Crankcase Splitting ...... Shift Pedal Installation ....
  • Page 324: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 325 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolt 87 in·lb Balancer Shaft Lever Bolt Breather Side Plate Bolt 0.60 52 in·lb Connecting Rod Big End Nuts see the text ← ← Breather Plate Bolts 87 in·lb Shift Drum Bearing Holder Bolts 106 in·lb...
  • Page 326 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 327 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Shift Drum Cam Bolt 106 in·lb Neutral Switch Shift Shaft Return Spring Pin Shift Pedal Mounting Bolt EO: Apply engine oil. G: Apply grease. MO: Apply molybdenum disulfide oil.
  • Page 328: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) Connecting Rod Big End Side 0.58 mm Clearance...
  • Page 329 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) Brown – – – 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) Black – – – 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) Blue –...
  • Page 330: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Bearing Puller: Bearing Driver Set: 57001-135 57001-1129 Outside Circlip Pliers: Flywheel Holder: 57001-144 57001-1313 Bearing Puller Adapter: Liquid Gasket, TB1216B: 57001-317 92104-1064 Bearing Driver, 32: Liquid Gasket, TB1207B: 57001-382 92104-2068...
  • Page 331: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...
  • Page 332: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Remove the lower crankcase bolts, following the specified sequence. ○ First, loosen the M7 bolts [A]. ○ Lastly, loosen the M9 bolts as shown sequence [1 ∼ 10] in the figure. • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase.
  • Page 333 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply a non-permanent locking agent to the threads of the breather plate bolts [A] and tighten them. Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the breather side plate [A] so that the plate hole [B] fit the projection [C] of the upper crankcase.
  • Page 334 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply a non-parmanent locking agent to the oil passage plugs [A], and tighten them. Torque - Oil Passage Plugs: 20 N·m (2.0 kgf·m, 15 ft·lb) • Install the oil passage plug [B] in the lower crankcase, and tighten it.
  • Page 335 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 336 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply molybdenum disulfide oil solution to the lower seating surface [A] on the copper plated washer [B] and threads [C] of the M9 bolts [D]. • Tighten the lower crankcase bolts using the following steps. ○...
  • Page 337 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • After tightening all crankcase bolts, check the following items. ○ Wipe up the liquid gasket that seeps out around the crankcase mating surface. ○ Crankshaft and transmission shafts turn freely. ○ While spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1st.
  • Page 338: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Balancer (see Balancer Removal) Crankshaft [A] Crankshaft Installation NOTICE If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 339 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts. • Do not apply any grease or oil to the cap inside and cap insert outside [B]. •...
  • Page 340 9-18 CRANKSHAFT/TRANSMISSION 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 341 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods (2) Rotation Angle Method If you do not have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts, nuts and connecting rods thor- oughly with a high flash-point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution.
  • Page 342: Crankshaft/connecting Rod Cleaning

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 343: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Measure the bearing insert/crankpin [A] clearance with plastigage (press gauge) [B]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○...
  • Page 344: Crankshaft Side Clearance Inspection

    9-22 CRANKSHAFT/TRANSMISSION 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 345: Crankshaft Runout Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear Inspection •...
  • Page 346 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 347: Balancer

    CRANKSHAFT/TRANSMISSION 9-25 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove the balancer [A] from the upper crankcase half. • Remove the oil seal [B]. Balancer Installation • Check that the rubber dampers [A] are in place as shown in the figure.
  • Page 348: Balancer Adjustment

    9-26 CRANKSHAFT/TRANSMISSION Balancer • Assemble the crankcase (see Crankcase Assembly). • Fill the oil seal lips with grease. • Install the new oil seal [A] so that its surface is flush with the surface of the crankcase. • Turn the balancer shaft so that its mark [B] faces down- ward (This photo is shown with the upside down).
  • Page 349: Starter Motor Clutch

    CRANKSHAFT/TRANSMISSION 9-27 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft •...
  • Page 350: External Shift Mechanism

    9-28 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Mounting Bolt [C] Shift Pedal [D] with Tie-rod [E] Shift Pedal Installation • Tighten: Torque - Shift Pedal Mounting Bolt [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) Shift Pedal [B] Washer [C]...
  • Page 351: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-29 External Shift Mechanism • Pull out the shift shaft assembly [A]. • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar and Spring [C] • Remove: Shift Drum Cam Bolt [A] Shift Drum Cam [B] External Shift Mechanism Installation •...
  • Page 352: External Shift Mechanism Inspection

    9-30 CRANKSHAFT/TRANSMISSION External Shift Mechanism • While prying the gear positioning lever [A], tighten the gear positioning lever bolt [B]. Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the shift shaft [A] so that the return spring pin [B] fits between the spring [C].
  • Page 353 CRANKSHAFT/TRANSMISSION 9-31 External Shift Mechanism • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If it is badly worn or shows any damage, replace it.
  • Page 354: Transmission

    9-32 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 355: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-33 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [C]: 57001-135 Bearing Puller Adapter [D]: 57001-317 • Discard the bearing. ○ For output shaft, remove the collar [B] together with the ball bearing. Transmission Shaft Assembly •...
  • Page 356 9-34 CRANKSHAFT/TRANSMISSION Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 357 CRANKSHAFT/TRANSMISSION 9-35 Transmission This page intentionally left blank.
  • Page 358 9-36 CRANKSHAFT/TRANSMISSION Transmission...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-37 Transmission 1. Output Shaft 2. Collar 3. Bearing 4. Bushing 5. 2nd Gear (39 T) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top Gear (23 T) 9. Toothed Washer ( 34) 10. 4th/3rd Gear (30 T/26 T) 11.
  • Page 360: Shift Drum And Fork Removal

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) Gear Positioning Lever (see External Shift Mechanism Removal) Bolts [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...
  • Page 361: Shift Fork/gear Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-39 Transmission Shift Fork/Gear Groove Wear Inspection • Measure the thickness of the shift fork ears [A], and mea- sure the width of the gear grooves [B]. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 362: Ball Bearing, Needle Bearing, And Oil Seal

    9-40 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 363 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 364: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 365 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Axle 13.0 93.7 Rear Sprocket Nuts Rear Axle Nut 11.0 79.7 HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 366: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.) (3.94 in.)
  • Page 367: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Head, 20 × 22: 57001-143 57001-1293 Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Attachment Jack: 57001-1252...
  • Page 368: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) Front Fender [A] (see Front Fender Removal in the Frame chapter) Front Caliper Mounting Bolts [B] (Both Sides) Front Calipers [C] (Both Sides) Bolt [D] Front Wheel Rotation Sensor [E] •...
  • Page 369: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the front axle. • Tighten: Torque - Front Axle: 127 N·m (13.0 kgf·m, 93.7 ft·lb) •...
  • Page 370: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove it. NOTICE 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 371: Wheel Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Install rear wheel rotation sensor (see Rear Wheel Rota- tion Sensor Installation in the Brakes chapter). • Check the rear brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). WARNING After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death.
  • Page 372: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Remove the front and rear axles (see Front/Rear Wheel Removal). • 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 373: 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 374: Tires

    10-12 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 375 WHEELS/TIRES 10-13 Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 376: 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 377: Hub Bearing

    WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] Special Tool - Inside Circlip Pliers: 57001-143 • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 378: Hub Bearing Inspection

    10-16 WHEELS/TIRES Hub Bearing • Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface flush [B] with the end of the hole.
  • Page 379 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 380: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 381 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 12.7 92.2 Drive Chain Guide Bolts 87 in·lb Rear Sprocket Nuts Rear Axle Nut 11.0 79.7 HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil.
  • Page 382: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA...
  • Page 383: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 384: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 385: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain Drive Chain Installation • Install the drive chain to the engine sprocket. • Install: Swingarm (see Swingarm Installation in the Suspension chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Engine Sprocket Cover (see Engine Sprocket Cover In- stallation) •...
  • Page 386 11-8 FINAL DRIVE Drive Chain • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. • Screw the handlebar [A] into body. • Turn the pin holder with wrench [B] clockwise to extract chain pin.
  • Page 387 FINAL DRIVE 11-9 Drive Chain • Turn the pin holder [A] by wrench clockwise until two pins of link come into groove of plate holders [B]. • Take off the plate holder. • Set the plate holder (B) [A] and cutting and riveting pin [B] as shown in the figure.
  • Page 388 11-10 FINAL DRIVE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plates Outside Width 19.35 ∼...
  • Page 389: Sprocket, Coupling

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Cover Removal • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Sprocket Inner Cover Bolts [A] Engine Sprocket Inner and Outer Cover [B] • Remove the engine sprocket outer cover screws [A] to separate the outer and inner cover [B].
  • Page 390: Engine Sprocket Installation

    11-12 FINAL DRIVE Sprocket, Coupling • Raise the rear wheel off the ground with the stand. • Loosen the drive chain (see Drive Chain Slack Adjust- ment in the Periodic Maintenance chapter). • Remove the drive chain from the rear sprocket toward the right.
  • Page 391: Coupling Installation

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Installation • Apply high-temperature grease to the following parts. Coupling Grease Seal Lip [A] Coupling Internal Surface [B] • Install: Collar [A] Coupling [B] Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 392: Coupling Bearing Inspection

    11-14 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 lip. Special Tool - Bearing Driver Set: 57001-1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close...
  • Page 393: Rear Sprocket Warp Inspection

    FINAL DRIVE 11-15 Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with the stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 395 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-3 Specifications ......................... 12-8 Special Tools .......................... 12-9 Brake Lever, Brake Pedal....................... 12-10 Brake Lever Position Adjustment..................12-10 Brake Pedal Position Inspection ..................12-10 Brake Pedal Position Adjustment..................12-10 Brake Pedal Removal ....................... 12-10 Brake Pedal Installation ....................
  • Page 396 12-2 BRAKES ABS Servicing Precautions ....................12-30 ABS Troubleshooting Outline.................... 12-32 Inquiries to Rider....................... 12-35 Self-diagnosis Outline ....................... 12-37 Self-diagnosis Procedures ....................12-37 Service Code Clearing Procedures................... 12-38 How to Read Service Codes..................... 12-41 How to Erase Service Codes .................... 12-41 Yellow ABS Indicator Light (LED) Inspection ..............
  • Page 397: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 398 12-4 BRAKES Exploded View...
  • Page 399 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Master Cylinder Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Front Brake Light Switch Screw 0.12 11 in·lb...
  • Page 400 12-6 BRAKES Exploded View...
  • Page 401 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Pipe Joint Nuts Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut Rear Caliper Pin Bolt Bleed Valve 0.80 69 in·lb Rear Brake Pad Pin Plug...
  • Page 402: Specifications

    12-8 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 54 mm (2.1 in.) below footpeg top –...
  • Page 403: Special Tools

    BRAKES 12-9 Special Tools Jack: Hand Tester: 57001-1238 57001-1394 Attachment Jack: Jack Attachment: 57001-1252 57001-1608...
  • Page 404: Brake Lever, Brake Pedal

    12-10 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 405: Brake Pedal Installation

    BRAKES 12-11 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation • Apply grease to the footpeg pivot shaft [A]. •...
  • Page 406: Calipers

    12-12 BRAKES Calipers Front Caliper Removal • Remove the clamp [A] (Left Side Only). • Loosen the banjo bolt [B] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [C], and detach the caliper [D] from the disc.
  • Page 407: Caliper Installation

    BRAKES 12-13 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. ○ Apply silicone grease to the rear caliper pin bolt. • Tighten: Torque - Caliper Mounting Bolts Front: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear: 22 N·m (2.2 kgf·m, 16 ft·lb) Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)
  • Page 408: Caliper Fluid Seal Damage Inspection

    12-14 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 409: Rear Caliper Holder Wear Inspection

    BRAKES 12-15 Calipers Rear Caliper Holder Wear Inspection The caliper body must slide smoothly on the rear caliper pin bolt [A] and sleeve [B]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
  • Page 410: Brake Pads

    12-16 BRAKES Brake Pads Front Brake Pad Removal • Remove: Pad Spring Bolts [A] Pad Spring [B] Pad Pin [C] • Remove the brake pads [A]. Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 411: Rear Brake Pad Installation

    BRAKES 12-17 Brake Pads • Pull up the caliper, remove the pad pin [A] and brake pads [B]. Rear Brake Pad Installation • Check that the pad springs [A], [B] are in place on the caliper or bracket. • Push the caliper piston in by hand as far as it will go. •...
  • Page 412: Master Cylinder

    12-18 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the rear view mirror (see Rear View Mirror Re- moval in the Frame chapter). • Remove the banjo bolt to disconnect the brake hose from the master cylinder (see Brake Hose Removal/Installa- tion).
  • Page 413: Rear Master Cylinder Installation

    BRAKES 12-19 Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin [A] with a new one. • Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) NOTE...
  • Page 414: Master Cylinder Inspection (visual Inspection)

    12-20 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 415: Brake Disc

    BRAKES 12-21 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. • Remove the gaskets (Front Only). Brake Disc Installation •...
  • Page 416: Brake Fluid

    12-22 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 417 BRAKES 12-23 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 418 12-24 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 419: Brake Hose

    BRAKES 12-25 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 420: Anti-lock Brake System

    12-26 BRAKES Anti-Lock Brake System Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator Light [A] ABS Hydraulic Unit [A] Fuse Box 2 [A]...
  • Page 421 BRAKES 12-27 Anti-Lock Brake System ABS Kawasaki Diagnostic System Connector [A] ABS Self-diagnosis Terminal [B]...
  • Page 422 12-28 BRAKES Anti-Lock Brake System ABS System Wiring Diagram 1. Joint Connector E 16. ABS Kawasaki Self-diagnosis System Con- 2. ECU nector 3. Rear Wheel Rotation Sensor 17. ABS Self-diagnosis Terminal 4. Rear Brake Light Switch 18. ABS Hydraulic Unit 5.
  • Page 423 2. Unused 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. ABS Kawasaki Self-Daignosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. ABS Self-Daiagnosis Terminal: GY 8. Front Wheel Rotation Sensor Signal Output: G/Y 9.
  • Page 424: Abs Servicing Precautions

    12-30 BRAKES Anti-Lock Brake System ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 425 BRAKES 12-31 Anti-Lock Brake System WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 426: Abs Troubleshooting Outline

    12-32 BRAKES Anti-Lock Brake System ○ The yellow ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the ignition switch OFF, then clear service code 42, which indicates a “Faulty front wheel rotation sensor”.
  • Page 427 BRAKES 12-33 Anti-Lock Brake System Even when the ABS is operating normally, the yellow ABS indicator light (LED) may light up under the conditions listed below. Turn the ignition switch OFF to stop the indicator light. If the motorcycle runs without erasing the service code, the light may light up again.
  • Page 428 12-34 BRAKES Anti-Lock Brake System ABS Diagnosis Flow Chart...
  • Page 429: Inquiries To Rider

    BRAKES 12-35 Anti-Lock Brake System Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 430 12-36 BRAKES Anti-Lock Brake System Pre-Diagnosis Inspection 1...
  • Page 431: Self-diagnosis Outline

    BRAKES 12-37 Anti-Lock Brake System Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code (19 codes including “Normal Code”) for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 432: Service Code Clearing Procedures

    12-38 BRAKES Anti-Lock Brake System • Remove the seat (see Seat Removal in the Frame chap- ter). • Turn the ignition switch to ON • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal, using a suitable lead. ○...
  • Page 433 BRAKES 12-39 Anti-Lock Brake System...
  • Page 434 12-40 BRAKES Anti-Lock Brake System Self-diagnosis Flow Chart...
  • Page 435: How To Read Service Codes

    BRAKES 12-41 Anti-Lock Brake System How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. ○...
  • Page 436: Service Code Table

    12-42 BRAKES Anti-Lock Brake System Service Code Table Service Light Problems Yellow ABS Indicator Light (LED) Code State After Start code (not fault) starts, turn off Rear inlet solenoid valve trouble (shorted or open, stuck valve) Rear outlet solenoid valve trouble (shorted or open, stuck valve) Front inlet solenoid valve trouble (shorted or open, stuck valve)
  • Page 437 BRAKES 12-43 Anti-Lock Brake System Service Light Yellow ABS Indicator Light (LED) Problems State Code Output fluid pressure sensor (front brake) trouble (offset abnormal) Power supply voltage for fluid pressure sensor abnormal (voltage abnormal, wiring shorted or open)
  • Page 438: Yellow Abs Indicator Light (led) Inspection

    12-44 BRAKES Anti-Lock Brake System Yellow ABS Indicator Light (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. • Refer to the meter operation Inspection in the Electrical System chapter.
  • Page 439: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    BRAKES 12-45 Anti-Lock Brake System ○ The ABS solenoid valve relay is built in the ABS Hydraulic Unit. Therefore the relay cannot be checked directly. • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code.
  • Page 440: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    12-46 BRAKES Anti-Lock Brake System If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and R/W lead terminal [B] in the ABS hydraulic unit lead connector [C]. Special Tool - Hand Tester: 57001-1394 If the wiring is open, replace or repair the harness (see ABS System Wiring Diagram).
  • Page 441: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    BRAKES 12-47 Anti-Lock Brake System Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) • Disconnect: ABS Hydraulic Unit Connector (see ABS Hydraulic Unit Removal) Front Wheel Rotation Sensor Connector (see Front Wheel Rotation Sensor Removal) • Check the wiring continuity of the BK/W lead and W/BK lead.
  • Page 442: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    12-48 BRAKES Anti-Lock Brake System • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
  • Page 443: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    BRAKES 12-49 Anti-Lock Brake System • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
  • Page 444: Output Fluid Pressure Sensor (front Brake) Wiring Inspection (service Code 83)

    12-50 BRAKES Anti-Lock Brake System Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) ○ The Output Fluid Pressure Sensor is built in the ABS Hy- draulic Unit. Therefore the sensor cannot be checked di- rectly. • Perform the Pre-Diagnosis Inspection 1 and 2 (see In- quiries to Rider).
  • Page 445 BRAKES 12-51 Anti-Lock Brake System • Remove: Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) Brake Hose Lower Ends (see Brake Hose Replacement in the Periodic maintenance chapter) • Clean the ABS hydraulic unit. NOTICE Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
  • Page 446: Abs Hydraulic Unit Installation

    12-52 BRAKES Anti-Lock Brake System • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Bolts [A] Bracket [B] ABS Hydraulic Unit [C] NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the ABS hydraulic unit.
  • Page 447: Front Wheel Rotation Sensor Removal

    BRAKES 12-53 Anti-Lock Brake System • Visually inspect the connector terminals [A]. Replace the ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.
  • Page 448: Rear Wheel Rotation Sensor Removal

    12-54 BRAKES Anti-Lock Brake System Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 449: Wheel Rotation Sensor Inspection

    BRAKES 12-55 Anti-Lock Brake System Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 450: Wheel Rotation Sensor Rotor Inspection

    12-56 BRAKES Anti-Lock Brake System Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.
  • Page 451: Fuse Inspection

    BRAKES 12-57 Anti-Lock Brake System Fuse Inspection • Remove the fuses (see ABS Solenoid Valve Relay Fuse (15 A)/ABS Motor Relay Fuse (25 A) Removal). • Refer to the Fuse Inspection in the Electrical System chapter.
  • Page 453 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment (Right Front Fork Only) ......... 13-9 Spring Preload Adjustment ....................13-9 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 454: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 455 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts 20.5 2.09 15.1 Front Fork Top Plugs 22.5 2.29 16.6 Piston Rod Nuts Cylinder Units Front Axle Clump Bolt AD: Apply adhesive (ThreeBond: TB1344N or equivalent). AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 456 13-4 SUSPENSION Exploded View...
  • Page 457 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bolt (Upper) Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Swingarm Pivot Shaft Nut 11.0 79.7 Swingarm Pivot Adjusting Collar Tie-rod Nuts Rear Shock Absorber Nut (Lower) Rocker Arm Nut G: Apply grease.
  • Page 458: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting (Right Front Fork 7 clicks from the fully clockwise position Only) (Usable range: 0 ←→ 12 clicks) Adjuster protrusion is 12 mm (0.47 in.) Fork Spring Preload Setting (Usable range: 4 ∼...
  • Page 459: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Fork Piston Rod Puller, M10 × 1.0: 57001-1058 57001-1298 Bearing Driver Set: Fork Spring Stopper: 57001-1129 57001-1374 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Bearing Remover Head, 15 ×...
  • Page 460 13-8 SUSPENSION Special Tools Fork Oil Seal Driver, 43: Needle Bearing Driver, 17/ 18: 57001-1530 57001-1609 Fork Spring Compressor: Needle Bearing Driver, 28: 57001-1540 57001-1610 Fork Spring Compressor: Bar: 57001-1587 57001-1694 Swingarm Pivot Nut Wrench: Fork Spring Compressor: 57001-1597 57001-1771 Jack Attachment: 57001-1608...
  • Page 461: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment (Right Front Fork Only) • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 7 clicks from the fully clockwise position.
  • Page 462: Front Fork Removal (each Fork Leg)

    13-10 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Upper Side Fairing (see Upper Side Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) • Loosen the upper front fork clamp bolt [A] and lower front fork clamp bolts [B].
  • Page 463 SUSPENSION 13-11 Front Fork • Holding the top plug [A] with a wrench [B], tighten the spring preload adjuster [C]. NOTE ○ After tightening, lift the top plug to make the space. • Install the clamps [A] as shown in the figure. NOTE ○...
  • Page 464 13-12 SUSPENSION Front Fork • Insert the projection of the protector [A] into the front fork bottom hall [B]. ○ For right front fork, remove the front axle clamp bolt. • Lift up the suitable jack [C] about 20 mm (0.79 in.) [D]. •...
  • Page 465 SUSPENSION 13-13 Front Fork • Drain the fork oil into a suitable container and remove the spring seat. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork. Special Tool - Fork Piston Rod Puller, M10 × 1.0 [B]: 57001 -1298 •...
  • Page 466 13-14 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: Right Front Fork 115 ±2 mm (4.53 ±0.08 in.) (from the top of the outer tube) Left Front Fork 114 ±2 mm (4.49 ±0.08 in.) (from the top of the outer tube) NOTE ○...
  • Page 467 SUSPENSION 13-15 Front Fork • Check the distance between the lower end [A] of the top plug [B] and lower end [C] of the rebound damping ad- juster with a vernier caliper [D] (Right Front Fork Only). 14.5 mm (0.571 in.) or more [E] •...
  • Page 468 13-16 SUSPENSION Front Fork If using the spring compressor (57001-1587) • Install the clamps [A] as shown in the figure. NOTE ○ Set the cutout [B] of the clamp to the plate [C] of top plug [D], pull up the outer tube [E] to hold it by the clamps, and then tighten the two bolts [F].
  • Page 469 SUSPENSION 13-17 Front Fork • Set the holder bar [A] and compression shafts [B]. • Screw in the nuts [A] until the piston rod nut comes out. • While holding up the top plug [A], insert the fork spring stopper [B] between the piston rod nut [C] and the slider. Special Tool - Fork Spring Stopper: 57001-1374 •...
  • Page 470 13-18 SUSPENSION Front Fork • Drain the fork oil into a suitable container and remove the spring seat. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork. Special Tool - Fork Piston Rod Puller, M10 × 1.0 [B]: 57001 -1298 •...
  • Page 471 SUSPENSION 13-19 Front Fork Oil Level (fully compressed, without spring) Standard: Right Front Fork 115 ±2 mm (4.53 ±0.08 in.) (from the top of the outer tube) Left Front Fork 114 ±2 mm (4.49 ±0.08 in.) (from the top of the outer tube) NOTE ○...
  • Page 472: Front Fork Disassembly

    13-20 SUSPENSION Front Fork • Check the distance between the lower end [A] of the top plug [B] and lower end [C] of the rebound damping ad- juster with a vernier caliper [D] (Right Front Fork Only). 14.5 mm (0.571 in.) or more [E] •...
  • Page 473 SUSPENSION 13-21 Front Fork • Separate the inner tube from the outer tube as follows. ○ Slide up the dust seal [A]. ○ Remove the retaining ring [B] from the outer tube. ○ Holding the outer tube [A] by hand, pull the inner tube [B] several times to pull out the outer tube.
  • Page 474: Front Fork Assembly

    13-22 SUSPENSION Front Fork Front Fork Assembly • Using a high flash-point solvent, clean off any oil or dirt that may be on the adhesive coating area. Dry them with a clean cloth. • Apply adhesive (ThreeBond: TB1344N or equivalent) to the threads of the cylinder unit [A].
  • Page 475: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-23 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A], and repair any dam- age. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.
  • Page 476: Rear Shock Absorber

    13-24 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting is the 2 turns out from the fully clockwise position.
  • Page 477: Rear Shock Absorber Installation

    SUSPENSION 13-25 Rear Shock Absorber • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack. Special Tools - Jack [A]: 57001-1238 Jack Attachment [B]: 57001-1608 WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over.
  • Page 478: Rear Shock Absorber Inspection

    13-26 SUSPENSION Rear Shock Absorber Rear Shock Absorber Inspection • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). • Visually inspect the following items. Smooth Stroke Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace •...
  • Page 479: Swingarm

    SUSPENSION 13-27 Swingarm Swingarm Removal • Remove: Rear Brake Hose Lower End (see Rear Caliper Removal in the Brakes chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mud Guard (see Mad Guard Removal in the Frame chapter) Rocker Arm (see Rocker Arm Removal) •...
  • Page 480 13-28 SUSPENSION Swingarm • Apply grease to the lips of the grease seals [A]. • Be sure to install the grease seals and sleeve [B] to the swingarm. • Fit the collar [C] on the grease seal of the left side. •...
  • Page 481: Swingarm Bearing Removal

    SUSPENSION 13-29 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Grease Seals [B] Sleeve [C] Circlip (Right Side) [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 482: Swingarm Bearing, Sleeve Inspection

    13-30 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing [B] in- stalled in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
  • Page 483: Tie-rod, Rocker Arm

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Upper Mud Guard (see Upper Mud Guard Removal in the Frame chapter) • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal).
  • Page 484: Rocker Arm Installation

    13-32 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the oil seals. • Replace the rocker arm nut, tie-rod nuts and rear shock absorber nut with new ones. • Tighten: Torque - Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb)
  • Page 485: Tie-rod And Rocker Arm Bearing Installation

    SUSPENSION 13-33 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearing [A] and oil seals with new ones. • Apply plenty of grease to the lips of the oil seals. • Install the needle bearings and oil seals position as shown in the figure.
  • Page 487 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-8 Steering Stem Warp Inspection ..................
  • Page 488: Exploded View

    14-2 STEERING Exploded View...
  • Page 489 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt 11.0 79.7 Upper Front Fork Clamp Bolts Handlebar Holder Mounting Nuts Steering Stem Nut Lower Front Fork Clamp Bolts 20.5 2.09 15.1...
  • Page 490: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Head Pipe Outer Race Driver, 54.5: Steering Stem Bearing Driver Adapter, 41.5: 57001-1077 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446...
  • Page 491: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 492: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing Bracket (see Upper Fairing Bracket Re- moval in the Frame chapter) Handlebars and Lower Handlebar Holder (see Handle- bar Removal) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer •...
  • Page 493: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...
  • Page 494: Steering Stem Bearing Lubrication

    14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A].
  • Page 495: Steering Stem Warp Inspection

    STEERING 14-9 Steering Stem Steering Stem Warp Inspection • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. Stem Cap Deterioration, Damage Inspection Replace the stem cap if its oil seal [A] shows damage.
  • Page 496: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clamp [A] Clutch Lever Clamp Bolts [B] Clutch Lever Assembly [C] Left Switch Housing [D] Handlebar Weight [E] Handlebar Grip [F] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Clamp [B] Right Switch Housing [C] Handlebar Weight [D]...
  • Page 497: Handlebar Installation

    STEERING 14-11 Handlebar • Remove: Bolts [A] (Both Sides) Lower Handlebar Holders [B] Lower Handlebar Holder Brace [C] Handlebar Installation • Install: Lower Handlebar Holders [A] Bolts [B] (Both Sides) • Install: Lower Handlebar Holder Assembly [A] Bolts [B] and Caps •...
  • Page 498 14-12 STEERING Handlebar • Install: Throttle Grip Throttle Cable Tips [A] Right Switch Housing ○ Fit the projection [B] into a hole [C] in the handlebars. • Tighten: Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Apply a non-permanent locking agent to the right handle- bar weight bolt.
  • Page 499 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Carrier..........15-16 Seats ..........15-8 Carrier Removal......15-16 Seat Removal ......15-8 Carrier Installation......15-16 Seat Installation ......15-8 Fenders ..........15-17 Fairings..........15-9 Front Fender Removal ....15-17 Lower Fairing Removal ....15-9 Front Fender Installation ....
  • Page 500: Exploded View

    15-2 FRAME Exploded View...
  • Page 501 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. CA and AU Models...
  • Page 502 15-4 FRAME Exploded View...
  • Page 503 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Frame Bolts Front Footpeg Bracket Bolts Sidestand Bracket Bolts Sidestand Nut R, S Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb Carrier Bracket Bolts Carrier Mounting Bolts 0.90 78 in·lb Rear Frame Guard Bolts 0.90 78 in·lb...
  • Page 504 15-6 FRAME Exploded View...
  • Page 505 FRAME 15-7 Exploded View 1. Other than GB WVTA (FULL H) and WVTA (78.2 H) Models 2. AU Model 3. CA Model L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 506: Seats

    15-8 FRAME Seats Seat Removal • Insert the ignition key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pull the seat forward. Seat Installation • Slip the seat hooks [A] under the brace [B] on the fuel tank bracket.
  • Page 507: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Bolts [A] Lower Fairing [B] Lower Fairing Installation • Installation is the reverse of removal, note the following. ○ Be sure install the grommets [A] and dampers [B]. Right Lower Fairing [C] Left Lower Fairing [D] Middle Fairing Removal •...
  • Page 508: Middle Fairing Installation

    15-10 FRAME Fairings • Remove the bolt [A]. • Pull the middle fairing [B] evenly outward to clear the pro- jections [C] and remove the fairing forward. Middle Fairing Installation • Installation is the reverse of removal, note the following. ○...
  • Page 509: Upper Side Fairing Removal

    FRAME 15-11 Fairings Upper Side Fairing Removal • Remove: Middle Fairing (see Middle Fairing Removal) Upper Fairing (see Upper Fairing Removal) Quick Rivet [A] • Remove: Quick Rivet [A] Bolts [B] • Disconnect the turn signal light lead connector [A], and remove the upper side fairing [B].
  • Page 510: Meter Cover Installation

    15-12 FRAME Fairings • Clear the projection [A] (both sides) and remove the meter cover assembly [B]. • Remove: Screws [A] and Washers Meter Unit [B] Meter Cover [C] NOTICE Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction.
  • Page 511: Windshield Installation

    FRAME 15-13 Fairings • Remove: Bolts [A] Washers [B] Brackets [C] Windshield [D] Windshield Installation • Installation is reverse of removal. Upper Fairing Bracket Removal • Remove: Middle Fairing (see Middle Fairing Removal) Upper Fairing (see Upper fairing Removal) Upper Side Fairing (see Upper Side Fairing Removal) Meter Cover (see Meter Cover Removal) Coolant Reserve Tank (see Coolant Change in the Peri- odic Maintenance chapter)
  • Page 512: Side Covers

    15-14 FRAME Side Covers Side Cover Removal • Remove: Seat (see Seat Removal) Upper Side Fairing (see Upper Side Fairing Removal) Bolts [A] with Washers • Pull the side cover [B] outward to clear the stoppers [C]. Side Cover Installation •...
  • Page 513: Seat Covers

    FRAME 15-15 Seat Covers Seat Cover Removal • Remove: Seat (see Seat Removal) Carrier (see Carrier Removal) Bolts [A] and Washers • Pull up the seat cover [B] to clear the hook portions [C] from the slots of the rear fender and remove it. Seat Cover Installation •...
  • Page 514: Carrier

    15-16 FRAME Carrier Carrier Removal • Remove: Seat (see Seat Removal) Carrier Bracket Bolts [A] and Collars Carrier Assembly [B] • Remove: Carrier Mounting Bolts [A] and Washers Carrier [B] Right and Left Carrier Brackets [C] Carrier Installation • Installation is the reverse of removal, note the following. ○...
  • Page 515: Fenders

    Electrical System chapter, GB WVTA (FULL H) and WVTA (78.2 H) Models) Screws [A] Bands [B] Starter Relay [C] Fuse Box 1 [D] Fuse Box 2 [E] Bracket [F] Clamp [G] Bolts [H] Immobilizer (Equipped Model)/Kawasaki Diagnostic System Connector [I]...
  • Page 516: Flap And Rear Fender Installation

    15-18 FRAME Fenders • Remove: Bands [A] Nuts [B] • Disconnect: Turn Signal Light Lead Connectors [A] Licence Plate Light Lead Connector [B] Tail Light Lead Connector [C] • Remove: Bolts [D] Clamps [E] • Pull up [A] front side of the rear fender [B], remove the rear fender rearward [C].
  • Page 517: Frame

    FRAME 15-19 Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 518: Guard

    15-20 FRAME Guard Upper Mud Guard Removal • Remove: Right Front Footpeg Bracket Bolts [A] • Remove: Quick Rivets [A] • Remove: Brake Hose Bracket Bolt [A] • Remove: Quick Rivet [A] Upper Mud Guard Bolts [B] Upper Mud Guard [C] Upper Mud Guard Installation •...
  • Page 519: Lower Mud Guard Removal

    FRAME 15-21 Guard Lower Mud Guard Removal • Remove: Upper Mud Guard (see Upper Mud Guard Removal) Lower Mud Guard Bolts [A] Lower Mud Guard [B] Lower Mud Guard Installation • Installation is the reverse of removal, note the following. ○...
  • Page 520: Sidestand

    15-22 FRAME Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove: Sidestand Switch Bolt [A] Nut [B] Sidestand Switch [C] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation •...
  • Page 521: Rear View Mirrors

    FRAME 15-23 Rear View Mirrors Rear View Mirror Removal • Slide the dust cover [A]. • Loosen the rear view mirror locknut (upper) [B], and re- move the rear view mirror stay [C] from the rear view mir- ror nut (lower) [D]. ○...
  • Page 523 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-3 Starter Motor Assembly ....16-50 Specifications ........16-10 Brush Inspection ......16-52 Special Tools and Sealant ....16-11 Commutator Cleaning and Parts Location........16-13 Inspection........16-52 Wiring Diagram (BR Model)....16-15 Armature Inspection.....
  • Page 524 16-2 ELECTRICAL SYSTEM Switch Inspection ......16-106 Fuel Level Sensor Inspection..16-109 Water Temperature Sensor Relay Box .......... 16-110 Inspection........16-107 Relay Box Removal ..... 16-110 Oxygen Sensor Removal ..... 16-107 Relay Box Installation ....16-110 Oxygen Sensor Installation ..16-108 Relay Circuit Inspection ....
  • Page 525: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View This page intentionally left blank.
  • Page 526 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 527 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Oxygen Sensor Front Brake Light Switch Screw 0.12 11 in·lb Licence Plate Light Mounting Screws 0.09 8 in·lb 5. Install the rear brake light switch spring so that the shorter side [A] faces upward. 6.
  • Page 528 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 529 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Intake Air Temperature Sensor Mounting Screw 0.12 11 in·ib Spark Plugs 87 in·lb Crankshaft Sensor Cover Bolts 106 in·lb Water Temperature Sensor 106 in·lb Timing Rotor Bolt Crankshaft Sensor Bolts 0.60 52 in·lb Starter Motor Cable Terminal Nut...
  • Page 530 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 531 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Cable Terminal Bolt 87 in·lb Neutral Switch Sidestand Switch Bolt 0.90 78 in·lb 4. Turn Signal Relay 5. Fuel Box 1 6. Fuel Box 2 7. ECU 8.
  • Page 532: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 44.8 V or more at 4 000 rpm 0.17 ∼ 0.25 Ω at 20°C (68°F) Stator Coil Resistance 14.4 ∼...
  • Page 533 ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: Grip: 57001-1394 57001-1591 Peak Voltage Adapter: Flywheel & Pulley Holder: 57001-1415 57001-1605 Lead Wire - Peak Voltage Adapter: Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1449 57001-1615 Needle Adapter Set: Stopper: 57001-1457 57001-1679...
  • Page 534: Special Tools And Sealant

    16-12 ELECTRICAL SYSTEM Special Tools and Sealant Key Registration Adapter: Liquid Gasket, TB1211F: 57001-1746 92104-0004 Rotor Holder: 57001-1757...
  • Page 535: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location 1. Timing Rotor 2. Crankshaft Sensor 3. Oxygen Sensor 4. Horn 5. Relay Box 6. ECU 7. Fuse Box 1 8. Fuse Box 2 9. Starter Relay 10. Battery 12 V 8 Ah 11. Rear Brake Light Switch 12.
  • Page 536 16-14 ELECTRICAL SYSTEM Parts Location 17. Neutral Switch 18. Sidestand Switch 19. Oil Pressure Switch 20. Air Switching Valve 21. Stick Coils 22. Spark Plugs 23. Immobilizer Amplifier (Equipped Models) 24. Turn Signal Relay 25. Starter Lockout Switch 26. Ignition Switch (Immobilizer Equipped Model: Including Immobilizer Antenna) 27.
  • Page 537: Wiring Diagram (br Model)

    ELECTRICAL SYSTEM 16-15 Wiring Diagram (BR Model) This page intentionally left blank.
  • Page 538 16-16 ELECTRICAL SYSTEM Wiring Diagram (BR Model)
  • Page 539 ELECTRICAL SYSTEM 16-17 Wiring Diagram (BR Model)
  • Page 540: Wiring Diagram (ca Model)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (CA Model)
  • Page 541 ELECTRICAL SYSTEM 16-19 Wiring Diagram (CA Model)
  • Page 542: Wiring Diagram (other Than Br And Ca Models)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (Other than BR and CA Models)
  • Page 543 ELECTRICAL SYSTEM 16-21 Wiring Diagram (Other than BR and CA Models)
  • Page 544: Precautions

    16-22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 545: Electrical Wiring

    ELECTRICAL SYSTEM 16-23 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 546: Battery

    16-24 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch to OFF. • Remove: Seat (see Seat Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. NOTICE Be sure to disconnect the negative (–) cable first. •...
  • Page 547 ELECTRICAL SYSTEM 16-25 Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns.
  • Page 548 16-26 ELECTRICAL SYSTEM Battery • Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE ○ Be careful not to have the battery fall down. •...
  • Page 549: Precautions

    Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...
  • Page 550: Interchange

    16-28 ELECTRICAL SYSTEM Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 551 ELECTRICAL SYSTEM 16-29 Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard 0.9 A × 5 ∼ 10 h (see following chart) Charge: Quick Charge: 4 A × 1 h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 552: Charging System

    16-30 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Disconnect the alternator lead connector [A]. • Place a suitable container under the alternator cover [A].
  • Page 553: Stator Coil Removal

    ELECTRICAL SYSTEM 16-31 Charging System Stator Coil Removal • Remove: Alternator Cover (see Alternator Cover Removal) Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C] • Remove the stator coil [D] from the alternator cover. Stator Coil Installation •...
  • Page 554: Alternator Rotor Installation

    16-32 ELECTRICAL SYSTEM Charging System • Hold the alternator rotor steady with the rotor holder [A] and stopper [B]. • Remove the rotor bolt [C] and washer. Special Tools - Grip [D]: 57001-1591 Stopper: 57001-1679 Rotor Holder: 57001-1690 If using the rotor holder (57001-1757). •...
  • Page 555 ELECTRICAL SYSTEM 16-33 Charging System • Install the alternator rotor [A] while turning [B] the starter clutch gear [C] clockwise. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • Install the washer and rotor bolt. •...
  • Page 556 16-34 ELECTRICAL SYSTEM Charging System • Install the washer and rotor bolt. • Tighten the alternator rotor bolt [A] while holding the alter- nator rotor steadily with the holder [B]. Special Tools - Grip [C]: 57001-1591 Rotor Holder: 57001-1690 Stopper [D]: 57001-1679 Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114 ft·lb) If using rotor holder (57001-1757).
  • Page 557: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Check that the ignition switch is turned off, and connect the hand tester [A] to the battery terminals [B].
  • Page 558 16-36 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch to OFF. ○ Remove the left side cover (see Side Cover Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A] (see alterna- tor Cover Removal).
  • Page 559: Regulator/rectifier Inspection

    NOTICE Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 560 16-38 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Frame Ground 2 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6. Main Fuse 30 A 7. Alternator 8. Regulator/Rectifier 9. Load...
  • Page 561: Ignition System

    ELECTRICAL SYSTEM 16-39 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is...
  • Page 562 16-40 ELECTRICAL SYSTEM Ignition System • Apply silicone sealant to the circumference of the alterna- tor lead grommet [A], and fit the grommet into the notch [B] of the lower crankcase securely. Sealant - Liquid Gasket, TB1211F: 92104-0004 • 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.
  • Page 563: Crankshaft Sensor Inspection

    ELECTRICAL SYSTEM 16-41 Ignition System Crankshaft Sensor Inspection • Support the fuel tank with a suitable bar (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the crankshaft sensor [A] (see Crankshaft Sensor Removal). • Set the hand tester [B] to the × 10 Ω range and connect (+) lead to the yellow lead and (–) lead to the black lead in the connector.
  • Page 564: Timing Rotor Removal

    16-42 ELECTRICAL SYSTEM Ignition System Timing Rotor Removal • Remove the crankshaft sensor (see Crankshaft Sensor Removal). • Remove the timing rotor [A]. ○ Holding the timing rotor with the flywheel & pulley holder [B] and remove the rotor bolt [C]. Special Tool - Flywheel &...
  • Page 565: Stick Coil Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...
  • Page 566: 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 to ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 567: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System 2nd Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch to ON and push the starter button. ○...
  • Page 568 16-46 ELECTRICAL SYSTEM Ignition System...
  • Page 569 ELECTRICAL SYSTEM 16-47 Ignition System Ignition System Circuit 1. Ignition Switch 14. Engine Ground 2. Engine Stop Switch 15. Battery 12 V 8 Ah 3. Spark Plugs 16. Starter Relay 4. Stick Coils 17. Main Fuse 30 A 5. Crankshaft Sensor 18.
  • Page 570: Electric Starter System

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). •...
  • Page 571: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-49 Electric Starter System • Install the starter motor cable [A] as shown. [B] Upward • Tighten: Torque - Starter Motor Cable Terminal Nut [C]: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Slide back the rubber cap to the original position. •...
  • Page 572: Starter Motor Assembly

    16-50 ELECTRICAL SYSTEM Electric Starter System • Pull out the brushes from the brush holder [A]. • Remove: Brush Springs [B] Starter Motor Terminal [C] Positive Brush Assy [D] Screw [E] Negative Brush Assy [F] Brush Holder Starter Motor Assembly •...
  • Page 573 ELECTRICAL SYSTEM 16-51 Electric Starter System • Install the brush springs [A] and insert the brushes [B]. • Apply thin coat of grease to the oil seal [A]. • Replace the O-rings [A] with new ones. ○ Apply grease to the O-rings. •...
  • Page 574: Brush Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System • Tighten: Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51 kgf·m, 44 in·lb) Brush Inspection • Measure the length of each brushes [A]. If any is worn down to the service limit, replace the brush assy.
  • Page 575: Brush Lead Inspection

    ELECTRICAL SYSTEM 16-53 Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. Right-hand End Cover and Negative Brushes [A] Terminal Bolt and Positive Brushes [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open.
  • Page 576 16-54 ELECTRICAL SYSTEM Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown in the figure. Special Tool - Hand Tester: 57001-1394 If the relay does not work as specified, the relay is defec- tive.
  • Page 577 ELECTRICAL SYSTEM 16-55 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Sidestand Switch 6. Joint Connector E 7. ECU 8. Joint Connector B 9. Frame Ground 3 10. Engine Ground 11.
  • Page 578: Lighting System

    16-56 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 579: City Light Bulb Replacement

    ELECTRICAL SYSTEM 16-57 Lighting System • Fit the dust cover [A] onto the bulb [B] firmly as shown. Good [C] Bad [D] • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). ○ Other Bulb: Repeat the above steps. City Light Bulb Replacement •...
  • Page 580: Headlight Removal/installation

    16-58 ELECTRICAL SYSTEM Lighting System Headlight Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Upper Side Fairings (see Upper Side Fairing Removal in the Frame chapter) Meter Cover (see Meter Cover Removal in the Frame chapter) Headlight Cover (see Headlight Cover Removal) Mounting Bolts [A]...
  • Page 581 ELECTRICAL SYSTEM 16-59 Lighting System • Push and turn the bulb [A] counterclockwise and remove • Replace the bulb with a new one. • 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 582 16-60 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 13. Headlight Circuit Relay 2. Tail/Brake Light (LED) 14. Dimmer Switch 3. License Plate Light 12 V 5 W 15. Passing Button 4. Joint Connector B 16. Fuse Box 1 5.
  • Page 583: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-61 Lighting System Turn Signal Light Bulb Replacement • Unscrew the screw [A] and remove the lens. • 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 584 16-62 ELECTRICAL SYSTEM Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how many times the lights blink for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not blink as specified, replace the turn sig- nal relay.
  • Page 585 ELECTRICAL SYSTEM 16-63 Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Rear Right Turn Signal Light 12 V 10 W 3. Rear Left Turn Signal Light 12 V 10 W 4. Joint Connector B 5. Frame Ground 3 6.
  • Page 586: Air Switching Valve

    16-64 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).
  • Page 587 ELECTRICAL SYSTEM 16-65 Air Switching Valve Air Switching Valve Circuit 1. Ignition Switch 2. Air Switching Valve 3. Joint Connector E 4. ECU 5. Frame Ground 1 6. Frame Ground 3 7. Engine Ground 8. Battery 12 V 8 Ah 9.
  • Page 588: Radiator Fan System

    16-66 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the left side cover (see Side Cover Removal in the Frame chapter). • Slide the dust cover [A]. • Disconnect the connector [B]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 589 ELECTRICAL SYSTEM 16-67 Radiator Fan System Radiator Fan Circuit 1. Ignition Switch 2. Fan Motor 3. Water Temperature Sensor 4. Joint Connector E 5. ECU 6. Frame Ground 1 7. Frame Ground 3 8. Engine Ground 9. Battery 12 V 8 Ah 10.
  • Page 590: Meter, Gauge, Indicator Unit

    16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Refer to the Meter Cover Removal/Installation in the Frame chapter. Meter Unit Disassembly • Remove: Meter Unit (see Meter Unit Removal/Installation) Screws [A] Lower Meter Cover [B] • Separate the meter assembly [A] and upper meter cover [B].
  • Page 591 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit • Indicate the ODO mode. • Check that the display [A] changes to the “km/h” and “mph” display each time by pushing the lower button while upper button pushed in. NOTE ○ Mile/Km Display can alternate between English and metric modes (mile and km) in the digital meter.
  • Page 592 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 1-2: Left Switch Housing Switching Inspection • Turn the ignition switch to ON. • By pushing the SEL button [A] each time, check that the display selects main display [B], power mode [C] and KTRC mode [D].
  • Page 593 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit • Select the power mode. • By pushing the upper button [A] or lower button [B] each time, check that the power mode symbol changes to going If the display function does not work, check the following parts.
  • Page 594: Meter System Inspection

    16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter System Inspection Check 2-1: Outside Temperature Inspection • Disconnect the outside temperature sensor connector [A] (see Outside Temperature Sensor Removal). • Connect the variable rheostat [B] to the BK/Y lead [C] and BL/R lead [D] terminals.
  • Page 595: Meter Unit Inspection

    ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Check 2-3: Battery Warning Indicator Inspection • When the battery condition is low voltage (10.8 ∼ 11.2 V or less), the battery symbol [A] and red warning indicator light (LED) [B] goes on. If the battery symbol and red warning indicator light (LED) goes on, charge the battery (see Refreshing Charge).
  • Page 596 16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Connect the terminal [6] to the battery (+) terminal. • Check the following items. ○ The tachometer needle [A] momentarily points their last readings and back to the minimum position. ○ All the LCD (Liquid Crystal Display) segments [B] appear for about 1 second.
  • Page 597 ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit Check 3-2: Meter Communication Line (Service Code 39) Check • Connect the leads in the same circuit as Check 3-1. • Wait 10 seconds and the yellow engine warning indicator light (LED) goes on. •...
  • Page 598 16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the red warning indicator light (LED) [A] starts blinking (Immobilizer Warning Indicator Light Blinking Mode). • Push the upper [B] and lower [C] buttons more than 2 second, within 20 seconds after the terminal [6] discon- nected.
  • Page 599 ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit • Check that the green left turn signal indicator light (LED) [A] goes on. If the green left turn signal indicator light (LED) does not go on, replace the meter unit. Check 3-5: Blue High Beam Indicator Light (LED) In- spection •...
  • Page 600 16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3-7: Green Neutral Indicator Light (LED) Inspec- tion • Connect the leads in the same circuit as Check 3-1. • Connect the terminal [2] to the battery (–) terminal. • Check that the green neutral indicator light (LED) [A] goes If the green neutral indicator light (LED) does not go on, replace the meter unit.
  • Page 601 ELECTRICAL SYSTEM 16-79 Meter, Gauge, Indicator Unit • Check that the oil symbol [A] and red oil pressure warning indicator light (LED) [B] goes on. If the oil symbol and red warning indicator light (LED) do not go on, replace the meter unit. Check 3-10: Yellow KTRC Indicator Light (LED) •...
  • Page 602 16-80 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3-12: Speedometer Inspection • Connect the leads in the same circuit as Check 3-1. • The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [10].
  • Page 603 ELECTRICAL SYSTEM 16-81 Meter, Gauge, Indicator Unit Check 3-15: Tachometer Inspection • Connect the leads in the same circuit as Check 3-1. • The engine speed (rpm) equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [11].
  • Page 604: Fuel Level Sensor Line Self-diagnosis Mode Inspection

    16-82 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Fuel Level Sensor Line Self-Diagnosis Mode Inspection NOTE ○ Usually when the open or short of the fuel level sensor circuit is detected, it becomes the Fuel Level Sensor Line Self-Diagnosis Mode. ○ The all segments of the fuel gauge [A] in the display will blink.
  • Page 605 ELECTRICAL SYSTEM 16-83 Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 16. ECU Fuse 15 A 2. Crankshaft Sensor 17. Fuse Box 2 3. Water Temperature Sensor 18. Meter Fuse 7.5 A 4. Neutral Switch 19. Fuel Level Sensor 5.
  • Page 606: Immobilizer System (equipped Models)

    • Remove: Seat (see Seat Removal in the Frame chapter) • Remove the immobilizer/Kawasaki diagnostic system connector cap [A]. • Connect the key registration adapter [A] and key registra- tion unit [B]. Special Tools - Key Registration Unit: 57001-1582...
  • Page 607 ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) • Insert the registered ignition key into the ignition switch, and turn it to ON. Verified ○ The red warning indicator light (LED) and the immobilizer warning symbol [A] blink to display the registration mode (go to the next step).
  • Page 608 16-86 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the red warning indicator light (LED) and the immobilizer warning symbol [A] blink to display the collation error. Immobilizer Amplifier Failure When Registered Ignition Key is Inserted. Ignition Key Collation Error •...
  • Page 609 ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) • Insert the ignition key 2 to the ignition switch and turn it to ○ If there is any problem in the registration, the red warning indicator light (LED) and the immobilizer warning symbol [A] blink to display the collation error.
  • Page 610 Immobilizer System (Equipped Models) • The red warning indicator light (LED) [A] goes off. • Remove the key registration unit, key registration adapter and install the immobilizer/Kawasaki diagnostic system connector cap. NOTE ○ Turn the ignition switch to ON with the registered ignition key.
  • Page 611 ELECTRICAL SYSTEM 16-89 Immobilizer System (Equipped Models) Spare Ignition Key Registration Flow Chart...
  • Page 612 Remove: Ignition Switch (see Immobilizer System Parts Replace- ment) Seat (see Seat Removal in the Frame chapter) • Remove the immobilizer/Kawasaki diagnostic system connector cap. • Connect the key registration adapter [A] and key registra- tion unit [B]. Special Tools - Key Registration Unit: 57001-1582 Key Registration Adapter: 57001-1746 •...
  • Page 613 ELECTRICAL SYSTEM 16-91 Immobilizer System (Equipped Models) Not Verified ○ The red warning indicator light (LED) and the immobilizer warning symbol [A] blink to display the collation error. Immobilizer Amplifier Failure Registered Ignition Key Collation Error • Turn to OFF the ignition switch and remove the new igni- tion key 1.